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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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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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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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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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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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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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

CAUTION
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 traces of 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 terminals / 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 installations 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.
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If the foregoing precautions are not fully understood,
clarification should be obtained from your nearest
Amara Raja representative.
The symbol at the left indicates an important message. If not followed,
damage to and / or impaired performance of the battery may result.
5.5 IMPORTANT MESSAGE

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.
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6 RECEIPT OF SHIPMENT
6.1 DELIVERY INSPECTION
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.
6.2 CONCEALED DAMAGE
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.
7 STORAGE PRIOR TO INSTALLATION
7.1 STORAGE LOCATION

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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 - 32⁰ C,
clean, dry location provided with a freshening charge interval detailed
in Section 7.1. Do not stack wooden crates or cases one above the other to
prevent damage to the batteries.
AMARON QUANTATM & HWS 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 as per below table.
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 charge is to be
given.
7.2 STORAGE INTERVAL
Charging
Average
Ambient
Temp0c
<27
27-32
32-37
37-42
42-47
06
4.5
03
2.25
1.5
13.8V - Boost 16 to 24 Hrs
Interval
(Months)
Recommended Freshening
Charge Voltage & Duration
Charging
Voltage – Volts
For Single Module
at 27°C
Duration(hrs) when
charged with
current limit of 25%
of Ah capacity
@C20 rate

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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 11.0.
Important Note: Wherever charging current is referred in this manual, the
following tabular charging current values to be consider for
corresponding HWS models.
The batteries are uniquely made of using PPCP/FRPPCP material which
will well suits for Tropical environment due to its properties such as lower
water permeability characteristics. This will help us in not losing higher
moisture from the batteries during its service when operating at tropical
Model Number
12HWS-388W 12Amps 24Amps
12HWS-440W 14.4Amps 36Amps
12HWS-540W 18Amps 45Amps
12HWS-730W 24Amps 60Amps
Min. Charging current Max. Charging current
Note: The charger/UPS should have protection against over charge and
discharge beyond prescribed end voltages. Deep discharges can cause
permanent damage to the battery. It is recommended that
interconnecting cable between battery and load shall be selected to
ensure a maximum drop of 30mV per meter length at the maximum rate
of discharge. All temperatures given in this Section should be considered
as average temperatures for the entire duration of the storage interval.
Charging Mode: Constant Potential with current limit.
7.3 BATTERY CONTAINER & COVER

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environments unlike other plastics such as ABS. Since the VRLA batteries
works under positive pressure to support superior oxygen recombination
in the battery, PPCP which is elastic in nature has bulging as a normal
property. This Elongation is due to material characteristics and it will not
have any adverse effects on battery performance when operated at
normal conditions as recommended by the manufacturers.
Prior to installation of the AMARON
QUANTATM & HWS battery system, a review
of this section is strongly recommended
8 GENERAL INSTALLATION CONSIDERATION
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.
8.1 BATTERY LOCATION

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Average Ambient
Temperature° C
Voltage Settings Volts Per Module (VPM)
Float
27° C 13.50 VPM 13.80 VPM
Boost
The AMARON QUANTATM & HWS 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 98% 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 QUANTATM & HWS batteries can be installed in close proximity
to electronic equipment provided that the heat generated by the
electronic equipment is removed by ventilation..
8.2 VENTILATION
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.
8.3 TEMPERATURE VARIATIONS

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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.
8.4 FLOOR LOADING
Where seismic conditions are anticipated, floor anchoring should be
provided. Such anchoring is responsibility of the end user.
8.5 FLOOR ANCHORING
Check parts received against the packing note.
Contact your local Amara Raja 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.
9 CABINET SYSTEM  INSTALLATION
9.1 CABINET ASSEMBLY INSTRUCTIONS

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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.
9.2 PLACEMENT OF BATTERIES
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 drops in the cable between the system and operating
equipment should not be more than 0.03V per meter length.
10 ELECTRICAL INSTALLATION
CONSIDERATIONS
10.1 CONNECTING CABLES
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
10.2 PARALLELING

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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.
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.
10.3 CONNECTION PREPARATION
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 as per below table and
complete all the connection of modules by installing the inter-tier &
module connections. Recommended Terminal Torque for tightening is
given in below table
10.4 CONNECTION TORQUE
Terminal Type
M5 7-8N-m (or) 62-71 Lb-inch
M6 11N-m (or) 100 Lb-inch
M8 13N- m (or) 115 Lb-inch
Recommended Terminal Torque
Caution: Do not make connections to the load at this time.

Battery terminal and inter-battery connections should be corrosion free
and tight for trouble-free operation. Periodically these connections should
be inspected to assure cleanliness and integrity.
Caution: Do not work on connectors with battery connected to charger or
load.
If corrosion is present, disconnect the connector from the terminal. Gently
clean the affected area using a brass brush or emery paper and follow all
directions as specified in section 10.2 and 10.3
All terminals and inter-battery connections should be re-torqueing at least
once in every six months. It is recommended to keep one inter tire
connector unconnected before connecting the end connections. After
connecting the charger/end connection inter tire connection can be made.
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10.5 CONNECTIONS
10.5.1 GENERAL
Visually check to see that all modules are connected positive (+) to negative
(–) throughout the battery string. Measure the total open circuit voltage
from positive string termination to negative string termination and also
record the individual module voltages. For the fully charged battery, the
voltage should be greater than 12.90 Volts
If the value for a battery is less than 12.60 Volts, contact your nearest Amara
Raja representative.
The bank voltage shall be equal to the sum of individual battery voltage.
10.5.2 CONNECTIONS CHECK