AMARA RAJA AMARON QUANTA 12HWS-388W Service manual

INSTALLATION AND
OPERATION INSTRUCTIONS

This document details procedures to be followed while
installing and operating AMARON QUANTATM & HWS
SMF-VRLA batteries. The procedures herein described
are meant for use by the customers of Amara raja
Batteries.
This document is a part of the documentation system in
Amara raja 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.
AMARON QUANTA - LIFE UNINTERRUPTED

AMARON QUANTA - LIFE UNINTERRUPTED
PAGE OF CONTENTS
Section 1 Introduction 1
Section 2 Brief Review of Technology 1
Section 3 Major Advantages of VRLA Batteries 2
Section 4
4.0
General Information
AMARON QUANTATM & HWS Batteries 3
5.1 Safety Alert 3
5.2 Sulphuric Acid Burns 4
5.3 Explosive Gases 4
5.4 Electrical Shock and Burns 4
5.5 Important Message 5
Section 5 Safety Precautions
6.1 Delivery Inspection 6
6.2 Concealed Damage 6
Section 6 Receipt of Shipment
7.1 Storage Location 6
7.2 Storage Interval 7
Section 7 Storage Prior to Installation

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PAGE OF CONTENTS
8.1 Battery Location 9
8.2 Ventilation 10
8.3 Temperature Variations 10
8.4 Floor Loading 11
8.5 Floor Anchoring 11
Section 8 General Installation Considerations
10.1 Connecting Cables 12
10.2 Paralleling 12
10.3 Connection Preparation 13
10.4 Connection Torque 13
10.5 Connections
10.5.1 General
10.5.2 Connections Check
14
14
10.6 Battery to Charger Connection 15
Section 10 Electrical Installation Considerations
9.1 Cabinet Assembly Instructions 11
9.2 Placement of modules (Batteries) 12
Section 9 Cabinet System - Installation

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PAGE OF CONTENTS
Section 11 Freshening Charge
12.1 Float Charge 16
11.1 Constant Voltage Method 15
12.2 Float and Boost Voltages 16
12.3 Recharge 17
12.4 Test discharge 18
Section 12 Operation
13.1 Equalizing Charge 18
13.2 Equalizing Frequency 18
Section 13 Equalization
14.1 Inspection and Monitoring Chart 19
14.2 Procedure for Recoupment of the Capacity 20
14.3 Ascertaining the State of Charge 21
Section 14 System Monitoring

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PAGE OF CONTENTS
Section 15 Pilot Unit and Records 22
Section 16 Tap Connections 23
Section 17 Temporary Non-use 23
24
25
26
28
Section 18 Do’s & Dont’s
Section 19 Unit Cleaning
Section 20 Trouble Shooting
Section 20 Battery Maintenance Report

Amara Raja Batteries Ltd, (ARBL) the largest manufacturer of stand by
Valve Regulated Lead Acid (VRLA) batteries in the Indian Ocean Rim,
comprising the area ranging from Africa and the Middle East to South
East Asia. Our State-of-the-art manufacturing units are located at Tirupati
& Chittoor with our Corporate Office in Hyderabad, India.
The production process is highly automated and microprocessor based
controlled systems ensures adherence to process parameters. The
products that leave the unit are thus of the highest quality possible. The
company was awarded the coveted ISO-9001 certification in 2015, ISO
14001 re- certification in 2015, and ISO 45001: 2018 to Quality, Environment
and Occupational Health and Safety Management Systems.
By employing latest generation technology and with a clear
understanding of current power back up requirements, Amara Raja has
become the benchmark in the manufacture of lead acid batteries for
different applications. Amara Raja Industrial Batteries offers a broad range
of battery solution in segments like UPS, Solar, Energy Storage Solutions
(ESS), Telecom, Railways, Defence & Motive Power. Amara Raja Batteries
Limited(ARBL) the first company to manufacture Valve Regulated
Lead-Acid (VRLA) batteries in India. They are engineered to provide the
performance reliability and consistency over the life of the product and
they offer a long battery life with minimal maintenance.
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01
1 INTRODUCTION
The electrode reactions in all lead acid batteries are basically identical. As
the battery discharges, the lead -dioxide (positive active material) and the
spongy lead (negative active material), both react with the sulphuric acid
(electrolyte) to form lead sulphate and water. During charge, this process
is reversed.
2 BRIEF REVIEW OF TECHNOLOGY

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02
In conventional lead acid batteries towards the end of charging, the
oxygen gas gets evolved at the +ve electrode and the hydrogen gas gets
evolved at the –ve electrode. These gases will bubble out through the free
electrolyte media and escapes into the environment, there by water are
lost from the battery. Hence periodic topping up of these batteries with
DM water is required.
In VRLA Batteries, the oxygen gas generated at the +ve plate is
transported in the gaseous phase through the absorbent microporous
glass mat (AGM) separator to the surface of the –ve plate. The oxygen gas
gets reduced by reacting with the charged active material, spongy lead, of
the –ve plate. There by the evolution of hydrogen gas is effectively
suppressed. Consequently, the VRLA batteries do not lose any water
under normal operation and therefore, no topping up is required. This
phenomenon is called the Oxygen Recombination Principle.
All VRLA cells are provided with self-resealing safety valves to release the
excess gases into the atmosphere under abnormal charging conditions.
Hence these batteries are named as valve regulated lead acid (VRLA)
batteries.
*Supplied in factory filled, charged and ready to use condition.
*No topping up is required.
*Spill proof and leak proof
*No corrosive fumes are emitted, hence user friendly
*Safe and Explosion proof.
*Easy to install & Environment friendly.
3 MAJOR ADVANTAGES OF VRLA BATTERIES

In normal use, AMARON QUANTATM & HWS 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 QUANTATM & HWS
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 Amara
Raja recommends that the instructions entitled “SAFETY PRECAUTIONS”
be reviewed thoroughly and strictly followed when working with AMARON
QUANTATM & HWS Batteries.
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03
4 GENERAL INFORMATION
4.1 AMARON QUANTATM & HWS BATTERIES
The safety alert symbol at the right appears throughout
this manual. Where the symbol appears, obey the
safety message to avoid personal injury.
Before proceeding with the unpacking, handling, Installation and
operation of this AMARON QUANTATM & HWS valve- regulated lead-acid
storage battery, the following general information should be reviewed
together with the recommended safety precautions.
5 SAFETY PRECAUTIONS
5.1 SAFETY ALERT
CAUTION

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.
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04
5.2 SULFURIC ACID BURNS
DANGER
SULFURIC ACID BURNS
Under abnormal usage and excessive
overcharging batteries can generate excessive
gases, which will be released pressure through
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.
5.3 EXPLOSIVE GASES
DANGER
EXPLOSIVE GASES
All installation tools should be adequately
insulated / covered with vinyl electrical tape, or
suitable non-conducting material to minimize
possibility of shorting across connections.
5.4 ELECTRICAL SHOCK AND BURNS
DANGER
ELECTRIC SHOCK