8
Section 8 - MAINTENANCE AND RECORD KEEPING
Maintenance and record keeping is critical to
battery life and warranty continuance.
Proper
maintenance will ensure that the batteries are
being correctly used and will be available when
needed. Proper record keeping will ensure that, if
there is a problem with a battery, the customer can
demonstrate the batteries were correctly used and
so maintain the warranty.
8.1
General Maintenance
General maintenance of the battery means keeping
the battery and surrounding area clean and dry.
Since CELLYTE 6-12TSG Solar batteries are of
low maintenance design, there is no addition of
water or specific gravity checks needed for the life
of the battery. The only required maintenance
action is an annual retorque of the battery
connections; see Table 1 in Section 5.5.1 for re
torque values.
Review Section 2.4 on Electrical
Shock before performing this action.
CAUTION: Use only insulated tools.
Do not use any solvents or strong cleaners on or
around the batteries. A dry brush may be used to
remove any dust accumulations.
If required, a
solution of 1 kg of baking soda in 4 liters of water
may be used as a multipurpose cleaner if more
stubborn stains or dirt accumulations are present.
Follow
the
rack
or
cabinet
manufacturer's
instructions for maintenance if required.
8.2
General Records
8.2.1 Installation Records
When the battery is first received, record:
- Date of receipt,
- Condition of the battery blocs,
- Open circuit voltage of each block,
- Date of installation
- Original P.O. number
- Installer (s)
- Equalization time and voltage
- Any unusual storage conditions.
- Individual block float voltages,
- Ambient temperature,
- Float current,
- Battery temperature,
- String float voltage
8.2.2 Maintenance Records
Twice per year, record the following :
- Block float voltages
- String voltage
- Float current
- Ambient temperature
- Battery temperature
- Battery conditions
- Any unusual charges or discharges - last 6
months.
Keep the above records in a safe place for review
by maintenance personnel.
Remember,
these
records are mandatory for any warranty claim on
the battery.
SECTION 9 - CAPACITY TESTING
9.1
General
Discharge testing of the battery is performed to
determine the battery capacity.
There are two
reasons for performing this test:
(1)
A ratings test discharge - the intention here is to
determine the percent of battery capacity as
compared to the rated capacity. This is typically an
8 hour discharge test.
(2)
A service test discharge - this test is to determine
the battery standby time under the actual load
conditions of intended battery usage.The ratings
test discharge is usually performed using a suitably
designed and sized load bank to provide a constant
DC current load to the battery.
The test is
performed for the specified period of time to an
end-point voltage per cell (usually 1.67 - 1.80 VPC)
with the ampere hour capacity of the battery
calculated by multiplying the load current by the
number of hours of run time.
The actual AH
capacity can be compared to the rated AH capacity
to determine percentage capacity. This type of test
is usually used as an acceptance test of the
battery.
The service test is usually performed by placing the
actual load on the battery and determining the
actual time the battery will support the load.
This
test is done, in the case of a UPS, by switching into
a test mode where the battery becomes the primary
source and the normal AC line becomes the back-
up.
If the load is not critical, the AC input can
simply be shut off to simulate a loss of power event
and total system operation can be verified as well.
A load bank can be used if the normal battery load
is well defined.
9.2 Test Procedure
The battery test procedure for either test is :
(1)
Ensure the battery is fully charged before capacity
testing and that all connections are clean and tight.
If the battery has not been on float for at least one
week, perform an equalization charge, return the
battery to float charge and allow at least 1 hour to
stabilize.
(2)
Prepare the load bank or test load system. Ensure
all temporary cable connections are secure and
connected
to
the
proper
polarity,
and
have
sufficient current carrying capacity.
(3)
Determine the battery temperature by measuring
and recording the temperature of every 6 blocs.
Average the readings to determine average battery
temperature. Measure the battery temperature in
the middle of the side (preferably) or the end wall of
the container.
(4)
If a ratings test is being performed, the load current
or power must be temperature corrected if the
battery temperature is significantly different from
20ºC. The formula for calculating corrected load is
Temperature corrected load = load at 20ºC x CF,
