Operational &

Maintenance
Guidelines of
Amaron Volt
Batteries
Battery Contents & features
Battery Contents
Battery Contents & Major Features
 Installation Process

• Pre Installation
• Space Consideration

• Floor Loading

• Receipt of Material

• Tools required

• Installation
• OCV Checking

• Terminal Connections

• Fixture of terminal flaps

• Post Installation
• Final check of systems

• Charging Considerations
Pre – Installation
 Space Consideration & Floor Loading

Space Consideration:

• Ensure proper ventilation

• After placement, make sure the

availability of service space for
batteries.

Floor Loading:

• Floor should be able to withstand

the battery bank weight.

• If load exceeds, assemble

batteries on a steel sheet of min.
5-mm thickness.
 Receipt of Materials

• Unpack the batteries from

package

• Check for physical damages

& leakages on batteries

• Install the batteries as per

the connection drawing

• Count accessories according

to the number of batteries /
pacing slip.
 Tools Required

• Digital Multi Meter

with 0.5% accuracy

• AC/DC Clamp meter

• Torque wrench with

extension rod.

• Spanners set (12-13)

• Socket (13No)

• Box spanner
Installation
 Installation Process

• Identify +Ve & -Ve terminals &

check OCV’s >2.10V/ Cell.

• Apply the petroleum gelly on

the terminals & ensure
connector length & fix.

• Tightness of connector at
terminal should be 11Nm for
M6 bolt & 16Nm for M8 bolt.

• Fix the TPA(terminal post

assembly to take off end
connection.

• Finally Fix the Front covers.

Post - Installation

12
 Final checking of systems

• Check all connections visually.

• Do not use tap connections.

TPA (Terminal
Plate assembly

• Numbering starts from +Ve. take

off terminal.

• Use Only Calibrated Instruments

(shunt, multi meter etc..)
Front
• Ensure proper cable size and Covers

crimping of cable lugs wherever

used. (Viz., at the cell connection,
at terminal plate assembly, at
loads. etc.)
 Final checking of systems

Sl.
Checks Remedial action
No

1 Physical damages, Cracking of cover & container Replace the cell

2 Acid leakage Cell may be damaged. Replace the cell.

3 Oxidation formed on terminal post. Clean with brash brush (or) Emery paper.

Torque the terminal bolts to 11Nm

16Nm(use
(usetorque
Torque
4 Terminal bolt torquing.
wrench)
If not, apply very thin layer after torquing the
5 Check for petroleum jelly on all battery terminals
terminal bolt

Over voltage cut off and under voltage trip in the Power plant
6 During Installation & Whenever necessary
(Over voltage cutoff: 2.33VPC, Under Voltage trip: 1.75 VPC)

Ripple and the regulation in the Power plant. (Ripple: <2% rms.
7 During Installation & Whenever necessary
Value, O/p Voltage Regulation: ±1%.)

8 Maintain battery record. Charge/discharge readings.

 Charging Settings

VRLA Batteries require Constant potential current limited type (SMPS) charger with the following features.

Mode 15-32⁰C Above 32⁰C Current limit set (Amps)

For 24Cells Singe Cell 24Cells Singe Cell

Min. 10% - 30% of rated
Float 54.0V 2.25V 53.5V 2.23V
AH capacity
Boost 55.67V 2.32V 55.2V 2.30V

Voltage Ripple <2% RMS & Temperature compensation Has to be activated

Over Voltage Cut-Off: 2.33 Volts per cell & 55.92Volts & under voltage cut Off- 1.75 VPC & 42Volts per 48Volts system
O&M Guidelines
O&M Guidelines
Do’s & Don’ts
 Do’s & Don’ts
DO’s
• Clean the batteries as and when dust accumulates. DON’Ts
• Keep the batteries away from heat source, sparks, fire etc., • Do not add water or acid
• For float application, Charge the batteries once in every
• Do not tamper the safety valves
three months @ 2.30 VPC for 24 hrs.
• Do not paste Sr. No Stickers on Vent plug
• For cyclic application, Charge the batteries once in every
one month @ 2.32 VPC for 24 hrs. • Do not mix the batteries of different capacities or

• Ensure to set Periodical Boost charge setting in active. makes

• Auto Float To Boost Setting has to be in Active mode. • Do not over tighten the terminal bolts

• Wherever cables are used ensure using proper cable size • Do not allow any metal objects to rest on the battery or
and crimping of the lug to the cable. fall across the battery terminals
• Check the vent plug tightness always in 90⁰ Direction. • Do not mix the batteries of different capacities or
• Tighten all terminal bolts to 16 Nm for M8 & 11Nm for M6. makes

• Re- torque all the terminal bolts once in every six months. • Do not mix ordinary conventional/low maintenance

• After discharge, recharge the batteries when power batteries with maintenance Free VRLA batteries
restores. • Do not install physically damaged cells
• Always use calibrated instruments for measurements.
Trouble Shooting
 Trouble Shooting

• Cause & Effect Analysis

• Difficulties with charging system

• Over charging

• Under charging

• Cracked (or) broken jars and covers

• Corroded terminals

• Effect of temperature
 Trouble Shooting

Cause and Effect Analysis

Low Voltage
Physical Damage
Improper Loading
Tap Connection Vent tamper / Loose & Unloading at site
/ Misplaced in secondary transport Poor Installation practice

Improper torque Insufficient

Charging
Physical damage Parameters
Battery Bank
Low
Improper Charging Loose connection back up
Tap Connection
Under Rated Power Improper torque
plant / module
Prolonged storage
Deep Discharge

High Amb temp Terminal Post Melt

Low Back Up
 Trouble Shooting

Charging at a higher voltage Cause: Charging at a Lower voltage Cause:

 Corrosion  Sulphation
 Dry-out of separator  Reduction in capacity during operation
 Water loss  Un-equalization voltage among the cells
 Increased Temperature

Cracked / Broken Covers Cause: Corroded Terminal Cause:

 Oxygen recombination will not take place  Sudden drop in voltage during charge/discharge
 Cell efficiency come down  Low capacity
 Heating of the terminal post

Temperature effect

Higher than normal: Lower than normal:

In Discharge In Charge In Discharge In Charge

 Higher capacity  Excessive over charge  Lower capacity  Under charging of the battery
 Higher rate of grid corrosion  Electrolysis of water  Sulphation takes place
 Shortened service life  Shortened life
 Trouble Shooting

Charging at a higher voltage Cause:

Corrective action:
 Float voltage to 2.25 Volts Per Cell / 54 volts for 48Volts System.
 Charging current limit to 10%(min) to 30 % (max.) of cell rated Ah capacity
 Sufficient recharge after a discharge

Cracked / Broken Covers Cause: Corroded Terminal Cause:

Corrective action: Corrective action:

Replace the cell(s) immediately Clean the terminal post with emery paper/brass brush as and when
noticed

Temperature effect
Corrective action:
To some extent this can be compensated by adjusting the charger voltage setting by -3 mV per cell per degree raise in the temperature
Vice versa.
Thank you