AMARA RAJA AMARON QUANTA 12AL007 User manual

IN S T A LL A T IO N AND O P E R A T IO N IN S TR U C T IO N S
Ref No: ARB- MAN-Quanta-13-001

This document details procedures to be followed while installing and operating AMARON
QUANTA
TM
SMF-VRLA batteries. The procedures herein described are meant for use by
the customers of AmaraRaja Batteries.
This document is a part of the documentation system in AmaraRaja Batteries Limited
and the procedures described in this manual are supportive to the quality manual.
Suggestions and recommendations on this manual may please be mailed to the
National Service Manager Channel Service at [e-mail]
The technical details in this manual may be changed/modified without prior
notice due to design improvements as per company’s continuous improvement
policy.

CONTENT INDEX PAGE
Section 1 - GENERAL INFORMATION
1.0 AMARON QUANTA
TM
Batteries 1
Section 2 - SAFETY PRECAUTIONS
2.0 Safety Alert 1
2.1 Sulfuric Acid Burns 1
2.2 Explosive Gases 1
2.3 Electrical Shock and Burns 2
2.4 Important Message 2
Section 3 - RECEIPT OF SHIPMENT
3.0 Delivery Inspection 2
3.1 Concealed Damage 3
Section 4 - STORAGE PRIOR TO INSTALLATION
4.0 Storage Location 3
4.1 Storage Interval 3
Section 5 - GENERAL INSTALLATION CONSIDERATIONS
5.0 Battery Location 4
5.1 Ventilation 4
5.2 Temperature Variations 4-5
5.3 Floor Loading 5
5.4 Floor Anchoring 5
Section 6 - CABINET SYSTEM - INSTALLATION
6.0 Cabinet Assembly Instructions 5
6.1 Placement of modules (Batteries) 5
Section 7 - ELECTRICAL INSTALLATION CONSIDERATIONS
7.0 Connecting Cables 6
7.1 Paralleling 6
7.2 Connection Preparation 6

7.3 Connection Torque 6
7.4 Connections 7
7.4.1 General 7
7.4.2 Connections Check 7
7.5 Battery to Charger Connection 7
Section 8 - FRESHENING CHARGE
8.0 Constant Voltage Method 7-8
Section 9 - OPERATION
9.0 Float Charge 8
9.1 Float and Boost Voltages 8
9.2 Recharge 9
9.3 Test discharge 9
Section 10 - EQUALIZATION
10.0 Equalizing Charge 9
10.1 Equalizing Frequency 9
Section 11 - PILOT UNIT AND RECORDS 9-10
Section 12 - TAP CONNECTIONS 10
Section 13 - TEMPORARY NON-USE 10
Section 14 - DO’S & DONT’S 11
Section 15 - UNIT CLEANING 12
Section 16 - TROUBLE SHOOTING 12
BATTERY MAINTENANCE REPORT 13-14
TECHNICAL SPECIFICATIONS 15

Section 1 - General Information
1.0 AMARON QUANTA
TM
Batteries
In normal use, AMARON QUANTA
TM
Batteries will not generate or release hydrogen and
oxygen gases, will not release acid mist and will not have acid leak. This is because AMARON
QUANTA
TM
Batteries are designed differently from conventional lead acid batteries in order to
provide maintenance - free operation. They are inherently safer than conventional lead acid
batteries. However, there is a possibility that under abnormal operating conditions, or as a
result of damage, misuse and /or abuse, these potentially hazardous conditions (gassing, acid
mist, and leaking electrolyte) can occur. Thus AmaraRaja recommends that the instructions entitled
“SAFETY PRECAUTIONS” be reviewed thoroughly and strictly followed when working with AMARON
QUANTA
TM
Batteries.
Section 2 - Safety Precautions
2.0 Safety Alert
The safety alert symbol at the right appears throughout this manual. Where the symbol appears,
obey thesafetymessage toavoid personalinjury.
CAUTION!
Before proceeding with the unpacking, handling, Installation and operation of this AMARON
QUANTA
TM
valve- regulated lead-acid storage battery, the following general information should be
reviewed together with the recommended safety precautions.
2.1 Sulfuric acid burns
Batteries contain sulfuric acid, which can cause burns and other serious injuries. In the event of
contact with sulfuric acid, flush immediately and thoroughly with water. Secure medical attention
immediately. When working with batteries, wear a rubber apron, rubber gloves and safety goggles or
other eye protecting equipment. These will help in preventing injury of contact is made with the acid.
2.2 Explosive gases
Under abnormal usage and excessive overcharging batteries can generate excessive gases, which will be
released pressure thru the vent plugs / safety valves area and any contact with spark/fire will lead to
excessive flames causing blindness and other serious injury. If the safety vent opens while the gases are
being generate (i.e. in the event of the charger malfunction / over charge) these explosive gases will be
released. Keep sparks flame and smoking materials away from the batteries area.

2.3 Electrical shock and burns
All installation tools should be adequately insulated / covered with vinyl electrical tape, or suitable non-
conducting material to minimize possibility of shorting across connections.
Never lay tools or other metallic objects on modules as it may result in shorting of battery leading to
explosions and personal injury.
Multi-battery systems attain high voltages therefore extreme caution must be exercised during
installation of a battery system to prevent serious electrical burns or shock. Loose or dirty connectors
/ connection can cause battery fires. Keep all connectors / connections clean and torque at proper values.
Keep the outside of batteries clean and dry Neutralize any acid corrosion with cloth moisture with a
solution of baking soda and water, then wipe off all tracesof soda.
Do not move or shift the cabinet once installed without first disconnecting load to the cabinet and all inter
cabinet connections. Refer wiring diagrams for location of these connections.
Do not lift the Batteries by “L” terminal / posts. Do not tamper with post seals, protective covers pressure
relief vents or other battery components.
Disconnect the DC circuits from the charging equipment & load before working on batteries. Ensure that
the personnel who stand the risk of working with batteries are prepared and equipped to take the
necessary safety precautions. These installation and operating instructions should be understood and
followed. Assure that you have the necessary equipment for the work, including insulated tools, rubber
gloves, rubber aprons, safety goggles and face protectors.
CAUTION!
If the foregoing precautions are not fully understood, clarification should be obtained from your nearest
AmaraRaja representative.
2.4 Important Message
The symbol at the left indicates an important message. If not followed, damage to and / or impaired
performance of the battery may result.
Section 3 - Receipt of Shipment
3.0 Delivery Inspection
Upon receipt of shipment unload and store the batteries in covered area. Do not expose them to direct sun
light, rain, dust, storm, etc. Immediately upon delivery, examine for possible damage caused in transit,
damaged packing material could indicate rough handling. Make a descriptive note on the delivery receipt
before signing. If battery damage is found, request an inspection by the carrier and file a damage claim
immediately. Any battery with post or seal damage should be replaced.

3.1 Concealed Damage
Immediately upon receipt of shipment examine all the batteries and cabinets for concealed damage. If
damage is noticed, immediately request an inspection by the carrier and file a concealed damage claim.
Any delay in notifying carrier may result in loss or no right to reimbursement for damages.
Section 4 - Storage Prior to Installation
4.0 Storage Location
Do not locate batteries in places exposed to direct sun light, rain dust, storm etc. Such exposure will cause
damage to plastic components and will reduce battery life drastically.
If the battery is not to be installed at the time of receipt, it is recommended that it to be stored indoors
at a temperature of 15⁰C - 32⁰C, clean, dry location provided with a freshening charge intervals
detailed in Section 4.1. Do not stack wooden crates or cases one above the other to prevent damage to the
batteries.
4.1StorageInterval
AMARON QUANTA
TM
batteries have a long shelf life provided that the following instructions are adhered to.
During the storage interval (i.e. between date of shipment and date of installation) a freshening charge
should be given once in every six - (6) months. Storage at elevated temperatures will result in accelerated
rates of self-discharges. The table given below shows the storage interval at the various elevated
temperatures before which a freshening charges is to be given.
CHARGING INTERVALS RECOMMENDED FRESHENING CHARGE VOLTAGE & DURATION
AVERAGE
AMBIENT
TEMP
0
C
INTERVAL
(MONTHS) Charging Voltage – Volts Duration (hrs) when charged
with current limit of 25% of
Ah capacity@C
20
rate
<27
27-32
32-37
37-42
42-47
06
4.5
03
2.25
1.5
For Single Module For Single Module
13.5-Float 13.8-Boost 16-24
Storage beyond these periods without charge can result in excessive sulphation of plates, which is
detrimental to battery performance and life. Instruction on how to apply a freshening charge are detailed
in 8.0
Note: All temperatures given in this Section should be considered as average temperatures for the entire
duration of the storage interval.

Section 5 - General Installation Consideration
Prior to installation of the AMARON QUANTA
TM
battery system, a
review of this section is strongly recommended.
5.0 Battery Location
It is recommended that the battery unit be installed in a clean, cool & dry location. Floor should be
reasonably level and able to support the battery weight. A location is having an ambient temperature of
27°C will result in optimum battery life and performance. Average ambient temperatures above 30°C will
result in reduction of battery life. Continuous operation above 50°C is not recommended
DO NOT INSTALL BATTERIES IN LOCATIONS WITHOUT ANY VENTILATION. When selecting the
location for installation of the battery, certain consideration must be followed. First, a designated aisle
space should be provided to permit initial installations as well as for service and surveillance. After
installation, any additional equipment installed should not compromise access to the battery system.
5.1 Ventilation
The AMARON QUANTA
TM
battery is a valve-regulated lead-acid battery, which is under normal
recommended charging, in a stationary application, does not vent any gases. Tests have confirmed that
more than 99% of gases generated are recombined within the battery. Under normal operating
conditions, no special ventilation and / or battery room is required.
NEVER INSTALL BATTERIES IN AIR TIGHT ENCLOSURES. This is because,
under abnormal operating conditions like misuse/malfunction of charger etc. there is a possibility that
the battery gets excessively overcharged. When this happen the hazardous gases, hydrogen and oxygen
are released from the battery and can cause water loss. Therefore, ensure proper ventilation is provided.
Normal ventilation, sufficient for human occupation, is adequate to avoid hazardous conditions.
AMARON QUANTA
TM
batteries can be installed in close proximity to electronic equipment provided that
the heat generated by the electronic equipment is removed by ventilation.
5.2 T e m p e r a t u r e V a r i a t i o n s
Sources of heat or cold directed on portions of the battery can cause temperature variations within the
strings resulting in cell voltage differences and eventual compromise on battery performance. Heat
sources, such as heaters, sunlight or associated equipment can cause such temperature variations.
Similarly, air conditioning or outside air vents should not directly influence portions of cell string
temperatures. Every effort should be made to keep temperature variations to a minimum.

Average Ambient
Temperature
°
CVoltage Settings Volts Per Module (VPM)
Float Boost
27
°
C
13.5 VPM
13.8 VPM
5.3FloorLoading
The floor of the area where the battery system is to be installed
should have the capability to support the weight of the battery
system, as well as any auxiliary equipment. The total battery weight will depend on the battery size,
number of modules, as well as module configuration involved. Prior to installation, a determination
should be made that the floor integrity is adequate to accommodate the battery system.
5.4FloorAnchoring
Where seismic conditions are anticipated, floor anchoring should be provided. Such anchoring is
responsibility of the end user.
Section6–CabinetSystem-Installation
6.0CabinetAssemblyInstructions
Check parts received against the packing note. Contact your local AmaraRaja representative if parts
appear incomplete. Identify missing parts by part number and parts description. Do not assemble if all
material is not at the installation site or parts do not comply with drawing.
Study the battery arrangement drawing for cabinet / rack assembly, then start assembly of parts like
frames, tiers, module restraint plates etc.
6.1PlacementofBatteries
Study the battery arrangement drawing to determine the proper location of the positive and
negative terminals of the battery and to determine the correct placement of the batteries in the
cabinet. From the battery arrangement drawing determine the number of batteries to be placed in each
row and tier. When installing modules in the cabinet, start on the back row of the lower tier for stability
and safety reasons. Place modules in cabinet so that the positive (+) of one unit connected to the
negative (–) of the next unit in accordance with the battery arrangement drawings. Standard spacing is 5
mm between modules.
Ensure that the Batteries to be installed always in vertical position only.

Section7-ElectricalInstallationConsiderations
7.0ConnectingCables
Cable size selection should provide the lowest voltage drop possible between the battery system and
operating equipment. Excessive voltage drop will reduce the desired support time of the battery system.
The maximum voltage drop in the cable between the system and operating equipment should not be
more than 0.03V per meter length.
7.1Paralleling
Where it is necessary to connect battery in parallel to obtain
Sufficient capacity, cable connections from the bus / load to each of the parallel strings is preferred
rather than inter-string paralleling. Cables should be sized to minimize voltage drop and for proper
current carrying capability. They should be as short as possible. However, the lengths of cables for all
of the systems being paralleled to the load should be equal in length and size to provide proper load
sharing on discharge, as well as satisfactory recharge with the same float voltage per string. Care
should be taken to ensure overall resistance of connection between batteries and equipment - bus are
consistent between strings.
7.2 Connection Preparation
Gently clean the contact surfaces only by using the brass brush / emery paper.
For mounting batteries into the cabinet refer to the battery arrangement drawings to determine the
quantity and correct positioning of the inter-unit and inter-tier connections.
Caution: Do not use wire brushes of any other type for contact surface cleaning.
7.3 Connection Torque
After preparing contact surfaces, install all connectors. Hand tight to allow for final alignment of modules.
Once final alignment is made all connections with hardware should be torque to 100 Lb-inch (or) 11 Nm
and complete all the connection of modules by installing the inter-tier & module connections.
Caution : Do not make connections to the load at this time.