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Introduction
BATTERY TYPES
BATTERY TYPES
Lead Acid
Nickel Cadmium
Nickel Iron
FUNCTIONS
Indication: Indicating lamps, fascia. Alarm For energizing the protection schemes.
Positive plates: Positive plates are made out of lead antimony alloy. LEAD DIOXIDE (PbO2) dark chocolate brown in colour
Negative plates: Negative plates are also made in the same way but they will be lighter in design and will be filled up with SPONGE LEAD (Pb) Bluish gray in colour. .
Separators: Separators are provided in between both plates. Separators should have insulating property porous enough to allow gas bubbles to pass through and inactive to acid and lead. Separators are made out of wood, hard rubber, glass fiber, micro porous plastic materials.
Electrolyte It is DILUTE SULPHURIC ACID (H2SO4) which fills the cell compartment to im-merse the plates completely . It is approximately 3 parts water and one part Sulphuric acid (H2So4). A solution of specific gravity 1.21 or near about.
Container Jars of lead acid cells are made of ebonite moulded plastic, ceramics, glass. Main criteria is that the container should be acid proof. Normally ebonite is made out of rubber 60% and sulphur 40%. Enough space will be left at the bottom for active material to fall down prevent it from touching the plates.
Principle of operation
DURING CHARGING
DURING DISCHARGING
Specific gravity of the acid decreases due to formation of water Voltage of the cell decreases
Insulators of Glass or porcelain are inserted between the stand and battery stand and flooring. Cleanliness is very important. Remove traces of corrosions promptly by cleaning with washing soda solution . All contact surfaces should be clean and give a thin coat of Vaseline. The illumination is very important to examine all cells . Light fitting provided inside the battery room should be explosion proof. These should be installed on the side walls and not on the ceiling.
No naked flame should be permitted in to the battery room since hydrogen released may cause an explosion if ignited by heat. Exhaust fans shall be provided for proper ventilation in order to prevent the formation of explosive concentration of hydrogen and sulphuric mist, which is dangerous to the health of the operating personnel. The inlet air should be free from pollutants such as chlorine, acetic acid and other such gases. Never should the entrance door be kept closed, as this will lead to a negative pressure developing in the battery room due to the continuous operation of the exhaust fans. The battery room floor and walls up to a height of one meter should be covered with acid resistant paint / tiles.
Hydrometers Thermometer Cell testing voltmeter Rubber gloves Goggles and face shields
- 2 Nos - 1 NO - 1 No - 2 Sets - 1 No - 1 No
Protective aprons
Electrolyte on the skin must be washed with plenty of soap and Water Electrolyte on the skin must be washed with plenty of soap and Water Electrolyte on cloth may be neutralized with dilute ammonia Electrolyte on cloth may be neutralized with dilute ammonia Electrolyte on the wood or insulators should be wiped clean and dry Electrolyte on the wood or insulators should be wiped clean and dry Electrolyte on the floor could be neutralized with powdered chalk. Electrolyte on the floor could be neutralized with powdered chalk. It electrolyte gets into the eyes wash with plenty of clean water It electrolyte gets into the eyes wash with plenty of clean water and get immediate medical attention and get immediate medical attention
If the electrolyte is consumed by mistake, take a drink of soap If the electrolyte is consumed by mistake, take a drink of soap Suds and backing soda in a glass of water Suds and backing soda in a glass of water
UNPACKING
Carefully lift the cell by holding it at the bottom and top. Do not lift cell/battery by the terminals. Carefully examine for any damage in transit. Cells must be stored in a cool and dry place, protected from the sun, rain and dust. The electrolyte should be stored in a separate place in the stores. All items must be stored only inside the building.
ACID PREPRATION
Acid to cool down to 30 degree Centigrade During cooling: Stir the acid at frequent intervals Store diluted acid in clean plastic jars
FILLING FILLING
Fill dilute sulphuric acid to each cell through the vent hole, till the black ring on the float stem is just visible over the crown of the float plug.
Do not over fill. Allow the cell to cool down for 12 to 18 hours and not more than 24 Hrs. Add more electrolyte as required to restore level.
FIRST CHARGE
Example: 60 AH at 10hrs rate battery Normal voltage - 2V Volume of acid - 2 litters approximately. Specific gravity of sulphuric acid - 1.190 0.005 at 27deg C. First charge: current rate - 2.4 amps Minimum no of hours - 80 hours.
Fault is discovered within the first twelve hours the plates may be recovered If fault is not discovered even after a longer period (say 50 hours) it will usually break the negatives and depreciate the positives.
CHARGING STEPS CHARGING STEPS Take individual cell voltage, specific gravity and temperature reading every four hours and record. Electrolyte temperature should not be allowed to rise above 40 C In case of power shut down or any other unforeseen exigencies, the total time shall be suitably extended Electrolyte level should be maintained at the specified limit by adding 1.190 Spec. Gravity acid When fully charged, 1) All the cells gas freely 2) Voltage and specific gravity approx constant for 3 conse-cutive hours. 3) The voltage reaches a final value of 2.5 to 2.55 V per cell and the specific gravity to 1.200 0.005.
In any case the charge must not be terminated until the specified ampere hour input is fed in to the battery, even if the voltage and specific gravity readings exceed those values. This is important for better performance of the battery. Electrolyte is to be adjusted to 1.200 0.005 at 27 C If specific gravity is above 1.205 add distilled water. If specific gravity is below 1.195 add 1.400specific gravity acid. Once again charge for a couple of hours and check the gravity again.
By adding 0.0007(7 points) to the hydrome-ter readings for every 1 centigrade temperature rise above 27 centigrade and Deducting 0.0007 for every one degree centigrade temperature decrease below 27 centigrade of the electrolyte SG 27 = SGt + (t 27) x 7 _ 10000 Where SG 27 is specific gravity at 27 deg C SGt is specific gravity at t deg C t is temperature of the electrolyte.
FIRST DISCHARGE
After completion of the first charge, the battery should be allowed to stand on open circuit for not less than 12 hours. Discharge should commence within the 24 hours Arrange load can be varied to maintain a constant current discharge equal to the rating of the battery at the selected rate. Read and record cell voltage and specific gravity every hour Maintain the discharge rate until the battery terminal voltage decrease to a value 1.85 volts of each cell (or) when the voltage across any one cell has fallen to 1.70 V, whichever is earlier. Check the capacity requirements After completion of discharge, the battery shall be recharged at normal current rate immediately.
%Capacity at 25 degree centigrade = Ta / Ts * 100 Ta : actual time of test Ts : rated time of test
Capacity at 27 deg C = C1 + C1 X R X (27 t) 100 Where C1 = Observed capacity at t deg C R = Variation factor t = average electrolyte temperature deg C
Capacities and final cell voltage at various rates of discharge Capacities and final cell voltage at various rates of discharge Sl no Rate of discharge Capacity Final cell voltage
1 2 3 4 5 6 7 8 9 10
C1 C2 C3 C4 C5 C6 C7 C8 C9 C10
50.0 63.3 71.7 78.2 83.3 87.9 91.7 95.0 97.9 100.0
1.75 1.78 1.80 1.81 1.82 1.83 1.83 1.84 1.84 1.85
The cells are to be charged once again at the normal charge rate up to gassing point (starting current of C/10 rate) and at reduced recharging current after gassing (finishing current of C/20 rate). The cells are considered to be fully charged when all cells gas freely and the cell voltage and specific gravity remains constant for 3 consecutive hours.
EFFICIENCY
Ah efficiency =
If the capacity obtained on the first discharge is less than the rated capacity, repeating the discharge / charge cycle 2 to 3 times is recommended, even if the rated capacity is obtained
If the battery is to stand idle, first give a full charge and disconnect it from circuit. Give a freshening charge once in a month during the idle period and also before connecting for service.
ROUTINE CHARGE
EQUALISING CHARGE
3 4 6 8 11 16
to to to to to to
8 12 16 24 34 48
Freshening charge will be given once in 3 months at half to full Freshening charge will be given once in 3 months at half to full normal rate current normal rate current
EQUALISING CHARGE
Interval in months 12 3 2 1
The charging current for this operation is maintained at about 4% of the rated 10 hour capacity.
Buckling of plates
Sedimentation
Grid corrosion
TEMPERATURE TEMPERATURE
It is not advisable to work batteries above 40 degree centigrade. It is not advisable to work batteries above 40 degree centigrade. Increase the chemical reaction Increase the chemical reaction The plates distort, deteriorate and become brittle The plates distort, deteriorate and become brittle Excessive evaporation of the water in the electrolyte Excessive evaporation of the water in the electrolyte
Decrease the lifetime of the battery Decrease the lifetime of the battery
Daily check of specific gravity and voltage of pilot cell Daily check of specific gravity and voltage of pilot cell Inter cell connector joints should be checked weekly once Inter cell connector joints should be checked weekly once
Specific gravity and voltage of all cells should be checked weekly once Specific gravity and voltage of all cells should be checked weekly once
The trickle charging current and voltage may be adjusted if neces-sary The trickle charging current and voltage may be adjusted if neces-sary in every hourly in every hourly
AGE IN YEARS
CURRENT IN mA / Ahr
1 - 2 2 - 4 4 - 6 6 - 8 8 - 10
1 2 3 4 5
The charger should be cut off while taking the reading of specific The charger should be cut off while taking the reading of specific gravity and Voltage gravity and Voltage
Load test This is carried out for 1 minute duration to ensure that Load test :: This is carried out for 1 minute duration to ensure that the battery condition once in 15 days the battery condition once in 15 days
During boost charging the float plug and vent plug or any one should be During boost charging the float plug and vent plug or any one should be in open condition in open condition
Adding of distilled water During the normal service operation water Adding of distilled water :: During the normal service operation water evaporates from the electrolyte considerably due to gassing. The level of the evaporates from the electrolyte considerably due to gassing. The level of the electrolyte should be maintained a mark 10mm above the top of the plates. electrolyte should be maintained a mark 10mm above the top of the plates.
In a bowl mix 50ml of silver nitrate ( Ag No3 ) with 50 ml of distilled water ( tested already ) and keep the solution free from sunlight. Whenever any new distilled water is to be tested, take 100 ml of the distilled Water under test and add few drop of the above solution . Pure distilled water will not form any precipitation on adding the solution. If any precipitation is found it is clear that the water is not pure.
When it is found that the specific gravity is not uniform, discharge the battery bank for a short duration of 15 min to 30 min at 10 hour rate current or even less and recharge thereafter at equalizing charging current, with a current equal to 4% of the AH capacity and voltage applied could go up to 2.35 to 2.40V per cell. A specific gravity adjustment may be done at the end of this equalizing charge, using only distilled water
RECMMENDATION RECMMENDATION
For batteries operating constantly on float / trickle charge system it is recommended that a discharge the battery at the 10 Hrs rate current for 2 Hrs and recharge at normal / finishing current until specific gravity stabilies at 1.200 at 27 degree.
When a battery is not charged sufficiently (or) when a battery is in continuous under charged condition for a longer duration it leads, to the positive or negative plates containing more sulphate, thus reducing the battery capacity. In such cases, the lead sulphate undergoes a physical charge. Plates affected in this way become lighter in colour, gas prematurely on charge. This is called plate sulphation. Such plates can not be satisfactorily reconditioned but some improvement may be effected by prolonged charging at a low rate. When the battery is left unattended in this condition the sulphation becomes permanent and very often irreversible. Fully charged specific gravity is 1.200 or 0.005 at 27 degree centigrade. Voltage reading should not fall below 1.85 volts Specific gravity reading should not fall below 1.600 [fall by 40 points]
LIMITATION
The DC bus voltage is about 10% higher than the rated voltage; The DC bus voltage is about 10% higher than the rated voltage; it is acceptable for most applications it is acceptable for most applications
The drop in the DC control and protection circuits, particularly, the breaker trip circuit must be well within 5% of rated DC voltage. The total loop burdens of CT cable leads are to be preferably around 1ohm Voltage drop = e = 2xRxI or
=2xLxI Kxq Where e = Voltage drop in volts R = Resistance in ohm (lead one way) I = Line current in amps L = Length in meter (lead one way) q = Conductor cross-section in sq-mm K = conductivity (for cu = 56, Al = 35)
LIMITATION
Output voltage value stable within + or 1% of the rated dc supply voltage throughout the dc load variation from 5% to 100%
Ac supply fluctuation of + or 10% frequency variation of + or 5% and combined voltage and frequency fluctuation of 10%.
A rectifiers comprising thee-phase bridge has inherently low ripple content of the order of 5%
Earth leakage shouldnt exceed 6 to 10 milliamp and if the leakage exceeds, a warning signal should be connected
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