Lead Acid Battery Commissioning

1. Inspection/check

           The battery installation and charging unit must be inspected for mechanical soundness. All bolted connections within the circuit must be properly tightened for optimum contact as set out in the operating instructions.

           The charging unit must be checked for operational readiness. Ensure that the polarity is correct.

            Before filling the cells ensure that the conditions as set out in DIN VDE 0510 Part 2 regarding installation and ventilation are observed.

             Should a higher charging current be used than permitted for the ventilation layout by start up charging, the ventilation in the battery room must be increased according to the loading current applied for the start-up period and for one hour afterwards, e.g. by additional portable ventilators. The same applies to occasional special battery charging processes.

2. Filling cells

              Acid with the density according to Table 1 must comply with the purity specifications according DIN 43 530 Part 2.

If concentrated sulphuric acid is supplied, the mixing instructions must be observed.

             The acid temperature should be in the range of 15°C to 30°C. Before filling the temperature must be measured and noted in the commissioning report.

              Aher removing the transport plugs or opening the vent plugs the cells must be filled to the lower electrolyte level mark using acid-resistant filling devices.

It is not permitted to use transport plugs when operating the battery. They must be replaced by vent plugs delivered with the batteries.

Higher temperatures reduce the electrolyte density and lower temperatures increase the electrolyte density. The associated correction factor is 0.0007 kg/l per K.

Example: Electrolyte density 1.23 kg/l at 35°C corresponds to a density of 1.24 kg/l at 20°C.

3. Reaction time

              Aher filling the cells a reaction time of 2 hours must be observed. Subsequently, depending on the total number of cells, the temperature and electrolyte density of at least 4 to 8 cells (pilot cells) must be measured and noted in the commissioning

report.

If the temperature rise is less than 5 K and the electrolyte density has not fallen more than 0.02 kg/l below the acid density, a commissioning charge as under 4.1 or 4.2 is adequate.

                Should one of the deviations be higher than an extended commissioning charge as under 4.3 is necessary.

4. Commissioning

                With non-transparent cell containers the vent plugs remain open in order to observe whether gassing is taking place evenly in all the cells towards the end of the charge.

                  It is important that the first charge is carried out to completion. This is only possible with a charging voltage above 2.35 V/cell. Interruptions should be avoided if possible. Commissioning should be recorded in the commissioning report overleaf.

During start-up the cell voltage of the pilot cells must be measured and on start-up completion the cell voltage, electrolyte density and temperature of all cells must be measured and noted with the time and date in the commissioning report.

  

                 The electrolyte temperature must not exceed 55°C, if necessary the charge operation must be interrupted.

4.1 Commissioning charge with constant voltage (IU chararteristic)

                   A charge voltage of 2.35-2.4 V/cell is required. The charge current on commencing the charge shouid be a minimum of 5 A per 100 Ah C10.

                   The electrolyte density only rises slowly during the charge. The charge time can therefore take several days before reaching a minimum electrolyte density of nominal electrolyte density -0.01 kg/l.

                    Subsequently switch to the float charge voltage as set out in the operoting instructions. The electrolyte density rises to the nominal density during operation.

4.2 Commissioning charge with constant (I chararteristic) or decreasing current (W characteristic)

The maximum permitted currents can be obtained from Table shows maximum permitted charging currents in A per 100 Ah C10 for I and W charging

Charging must continue until

1. All cells have reached a minimum of 2.6 V
2. The electrolyte density in all cells has risen to
3. The nominal value of ± 0.01 kg/l and these cease to rise over a further period of 2 hours.

Subsequently switch to the floot charging voltage as set out in the operating instructions.

4.3 Extended commissioning charge

                  Extended storage or climatic influences (humidity, temperature fluctuations) reduce the charge state of the cells. This makes an extended commissioning charge along the following procedure necessary:

1. Charge at 15 A per 100 Ah C10 until 2.4 V/cell is achieved (ca. 3 - 5 hours),
2. Charge for 14 hours with 5 A per 100 Ah C10 (voltage exceeds 2.4 V/cell),
3. Interrupt for one hour,
4. Charge for 4 hours with 5 A per 100 Ah C10.

Repeat items 3 and 4 until

— all cells have reached a minimum 2.6 V

— the electrolyte density in all cells has risen to

the nominol value of ± 0.01 kg/l and these

cease to rise for a further 2 hours.

Subsequently switch to the float charge voltage

1. as set out in the operating instructions.

4.4 Electrolyte level adjustment

                 On completion of commissioning top up with acid to bring the electrolyte level to the upper electrolyte level mark.

4.5 Electrolyte density adjustment

                 If the electrolyte density at the end of commissioning is too high, reploce part of the electrolyte with purified water as specified in DIN 43 530 Part 4. The comparative electrolyte density in individual cells should not deviate more than 0.01 kg/l. With greater deviations adjust the electrolyte density and then carry out an equalizing charge as set out in the operating instructions.