Regal Electro X-CEL User guide

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INSTRUCTION AND OPERATIONS MANUAL
VALEN X-CEL 6-12V

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INSTRUCTION AND OPERATIONS MANUAL
VALEN X-CEL 6-12V
TABLE OF CONTENTS
SECTION
CONTENT
PAGE
SECTION
CONTENT
PAGE
1.0
GENERAL INFORMATION
3
6.0
OPERATION
6
1.1
Battery Characteristics
3
6.1
Initial Charge
6
6.2
Float Voltage
7
2.0
SAFETY INFORMATION
3
6.2.1
Float Voltage Requirements
7
2.1
General Information
3
6.2.2
Float Temp. Compensation
7
2.2
Sulphuric Acid
3
6.3
Maximum Charge Current
7
2.3
Gassing
3
6.4
Recharge
7
2.4
Electrical Shock
3
6.5
Equalisation Charge
8
3.0
RECEIPT OF EQUIPMENT
44
7.0
STORAGE
8
3.1
Delivery Inspection
4
3.2
Hidden Damage
4
8.0
MAINTENANCE & RECORDS
8
8.1
General Maintenance
8
4.0
STORAGE
4
8.2
General Records
8
4.1
General
4
8.2.1
Installation Records
8
4.2
Short Term Storage
4
8.2.2
Maintenance Records
8
5.0
INSTALLATION PROCEDURE
4
9.0
CAPACITY TESTING
9
5.1
Battery Location
4
9.1
General
9
5.1.1
Temperature
4
9.2
Test Procedures
9
5.1.2
Temperature Variation
4
9.3
Discharge Test Notes
10
5.1.3
Ventilation
4
5.1.3.1
Battery Temp. Variation
4
10.0
MAINTENANCE REPORT
11
5.1.3.2
Ventilation and Gassing
5
5.1.4
Floor Loading
5
11.0
BATTERY REPORT
12
5.2
Seismic Considerations
5
5.3
Installation - Cabinets
5
5.4
Installation - Racks
5
5.4.1
Existing Racks
5
5.4.2
New Racks
5
5.4.3
Installation
5
5.5
Electrical Connections
5
5.5.1
Cabling Recommendations
5
5.5.2
Terminal Preparation
6
5.5.3
Connector Installation
6
5.5.4
Voltage Checks
6
5.5.5
Battery to Charger Connection
6
5.5.6
Paralleling of Batteries
6

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SECTION 1 - GENERAL INFORMATION
1.1 VALEN X-CEL Battery Characteristics
The VALEN X-CEL Battery is a valve regulated lead-acid
recombinant battery designed for stationary applications.
The X-CEL battery uses Absorbed Glass Mat (AGM)
technology. This type of battery has no special ventilation
or handling requirements. Since the electrolyte in the
battery is immobilised, the batteries are considered dry
batteries and can be handled and shipped accordingly.
SECTION 2 - SAFETY INFORMATION
2.1 General Information
Lead acid batteries require care in installation and
maintenance. Unsafe installation or maintenance
procedures can cause severe injury or death. Electrical
shock or burns, acid burns and fire can result if proper
safety precautions are not followed. The following
precautions apply to all battery installation and
maintenance work.
Disconnect all power before attempting to install,
remove or perform maintenance work. When on
charge, float voltages must be measured, be
particularly careful because shorting a battery at this
time can cause not only personal injury but severe
equipment failure also.
Do not tamper with any parts of the battery including
cover, vents, terminal covers, etc.
Keep batteries clean and dry. Use ½kg of baking soda
in 4L of water to neutralise any possible acid. Do not
use cleaners or solvents on any part of the battery. Do
not allow excessive dust to accumulate on the battery
or cabling.
Keep battery connectors clean, greased and tight. A
loose connection can reduce battery standby time and
cause battery fires.
2.2 Sulphuric Acid
The VALEN X-CEL Battery is a lead acid battery and
contains sulphuric acid in diluted form. Since the
electrolyte is immobilised, in the event of a case rupture,
no liquid acid will leak or run from the battery. However,
if the internal components of the battery are touched or
handled, contact with the acid will result.
CAUTION! Sulphuric acid can cause burns and serious
injury if it comes in contact with your skin or eyes. In the
event of contact with sulphuric acid, flush thoroughly
with water and neutralise any residual acid with baking
soda (1kg in 4L of water). Seek medical attention
immediately. Do not handle batteries that have been
dropped or where the container has been ruptured
except while wearing rubber gloves. Do not try to
disassemble a battery.
2.3 Gassing
All lead acid batteries emit some gases during charging
and float operation. Conventional flooded batteries
release all the gases produced to the environment
whereas valve-regulated batteries re-combine most of
the gases internally, releasing very little to the
environment. Compared to a flooded battery of equal
capacity, a VALEN X-CEL Battery releases a gas volume of
1% or less than the flooded battery. Due to this
characteristic, no special ventilation is required under
normal usage conditions. Since some gas is released from
lead acid batteries, never charge or use batteries in an
unventilated space or container. This gas consists of
mostly hydrogen gas and can explode if ignited in a
confined area or space. Keep sparks, flame or any other
ignition source away from batteries.
CAUTION! Hydrogen gas can explode and cause serious
injuries and fire. Do not allow any flame or ignition
source near batteries. Always allow some ventilation
around operating batteries; contact REGAL ELECTRO if
there are any questions regarding gassing or
ventilation.
2.4 Electrical Shock
Batteries store large amounts of electrical energy. Even a
discharged battery can deliver a high short circuit
current. Keep all metallic objects away from the battery
terminals.
Multi cell systems can attain lethal voltages. Remove all
jewellery before working on batteries. Cover all tools with
vinyl electrical tape to minimise the possibility of shorting
a battery during installation. Never lay tools or other
metallic objects on batteries. Do not allow construction
work over batteries to proceed unless the battery is
protected by insulating rubber mats.
CAUTION! Shorting a battery can cause serious injury,
fire or an explosion. Do not attempt to work on a
battery unless you are familiar with battery installation
procedures and have adequate safety information and
equipment. Read this manual thoroughly before
attempting to install the battery. If there are any
questions about safety, contact REGAL ELECTRO before
installing the batteries. Safety is always the primary
concern.

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SECTION 3 - RECEIPT OF EQUIPMENT
3.1 Delivery Inspection
Immediately upon delivery, inspect the batteries for
damage caused in transit. Damaged pallets or packing
material or disarrayed batteries could indicate rough,
improper handling in transit. Describe in detail (take
photographs) any damage on the delivery receipt before
signature. If any damage is found, contact the carrier
immediately, request an inspection, and file damage
claim.
3.2 Hidden Damage
Within 10 days of receipt, inspect all batteries for hidden
damage. Measure and record open circuit voltages
(OCV’s) If any damage is found, request an inspection by
the carrier and file a hidden damage claim. Do not delay
this step as it may result in a loss of right of
reimbursement for hidden damages.
SECTION 4 - STORAGE
4.1 General
Do not store batteries outside, exposed to the elements.
Store indoors in a cool, dry location. Do not store
batteries in temperatures over 30°C. The recommended
storage temperature is 20°C or less. Do not stack pallets
or allow any other material to be stored on top of the
pallets or possible battery damage may occur. Do not
store where the possibility of metallic objects falling on
the battery may occur.
4.2 Short Term Storage
If the batteries are to be stored for 6 months or less at
20°C, before being put into service, nothing need be done
at this time. If the batteries are to be stored for longer
than 6 months, at temperatures greater than 20°C, or
installation is delayed beyond expected time, a storage
charge may be required. A storage charge is an
equalisation charge applied to a battery that is stored in
open circuit (not float charging) condition. See section 6.5
for details.
If the storage temperature is 20°C or less, VALEN X-CEL
Batteries must be charged at least every 6 months while
in storage. For every 8°C increase above 20°C, the storage
time between charges is cut in half. Therefore at 28°C the
maximum storage time is 3 months. At 25°C the
maximum storage time would be 4-5 months. Storage of
batteries beyond the recommended temperatures or
storage time, without charging, can result in loss of
capacity, cell shorting and loss of float life. It can also
void the battery’s warranty. Keep careful records of
battery storage time and handling.
SECTION 5 - GENERAL INSTALLATION PROCEDURES
CAUTION! Before attempting to install VALEN X-CEL
Batteries, study this section and the section on safety
thoroughly. Failure to do so could result in personal
injury and battery or equipment damage.
5.1 Battery Location
5.1.1 Temperature
Battery location is very important in determining life and
performance of the battery. The ideal environment would
be a dry, indoors, temperature regulated area. The ideal
operational temperature is 20°C.
Operation at temperatures below this will result in a loss
of battery performance and may result in a larger, more
costly battery being needed. Operation at temperatures
above 20°C will result in loss of battery operation life. For
every 8°C rise in battery temperature above 20°C, the life
of the battery will be cut in half. For example, the VALEN
X-CEL is designed for a 10 year float service life at 20°C. If
the battery were to be continuously operated at 28°C, the
life expectancy would be halved.
5.1.2 Temperature Variation
Maintaining temperature balance across the string is
very important for maximum battery life. The difference
between the maximum and minimum block temperature
in a series string can be no more than 3°C. Excessive
temperature variation will result in the need for
equalisation and will shorten battery life. Sources of
battery temperature variation can be placement of the
battery system near a heat source such as radiators,
power equipment, windows or heating vents. Air
conditioning vents can also cause temperature variations.
It is recommended that the battery location be designed,
engineered and monitored to minimise temperature
variations.
5.1.3 Ventilation
Proper ventilation of VALEN X-CEL Batteries is important
for two reasons:
1. To minimise battery temperature variations
2. To minimise build up of potentially explosive hydrogen
gas.
5.1.3.1 Ventilation & Battery Temp. Variation
Recombinant batteries such as VALEN X-CEL Batteries,
give off a small amount of heat during charging and float
operations. Proper ventilation is important to remove this

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heat and to prevent temperature differences from arising
in the string. If the batteries are installed in a cabinet, it
should be designed to allow unobstructed air circulation
and prevent temperature build-up. Use angle iron
support rails instead of shelves. If the batteries are on
racks, sufficient air circulation should be present to
prevent temperature-layering effects. In an improperly
designed room, there can easily be a 5°C difference in
temperature between the floor and the ceiling. If this
difference exists in a series string, it will result in a need
for equalisation and in reduced battery life.
5.1.3.2 Ventilation and Gassing
As noted, lead acid batteries emit small amounts of gas
during normal charging and floating. The gas
composition while on float is approx. 80% by volume
hydrogen with the remainder being oxygen.
CAUTION! Hydrogen has can be explosive. Never install
batteries in an airtight enclosure. Ventilation must be
provided to remove this hydrogen gas. Allow about
1L/hour/battery of air exchange to prevent hydrogen
accumulation.
5.1.4 Floor Loading
Before installing the batteries, it should be ascertained
that the floor has the capability to support the weight of
the battery, rack or cabinet and related equipment. The
total system weight will be the sum of the batteries, rack
or cabinet plus 5% for the battery connectors. It is the
responsibility of the installer to ensure adequate floor
load carry in capabilities.
5.2 Seismic Considerations
VALEN X-CEL Batteries are capable of withstanding
seismic events of UBC Zone 4 magnitude when properly
installed in a suitably designed cabinet or rack. When
seismic capability is desired, suitable floor anchoring
should be provided. Proper floor anchoring is the
responsibility of the installer.
5.3 Installation - Cabinets
When installing VALEN X-CEL Batteries in cabinets, follow
the recommendations of section 5.1.3.1 regarding
cabinet ventilation. Ensure that the batteries are
electrically insulated from the cabinet frame. Standard
battery spacing is 12mm minimum between battery
blocks. If the cabinets are to be seismic rated, the
batteries must be firmly attached to the cabinet to
prevent battery shifting during a seismic event. Proper
installation is the responsibility of the installer.
5.4 Installation - Racks
5.4.1 Existing Racks
When VALEN X-CEL Batteries are to be installed on
existing racks, ensure the racks are:
1. Of proper size for the intended battery
2. Have sufficient weight carrying capability for the
intended battery, including seismic considerations, and of
sufficient size to hold the number of blocks (plus the
12mm needed between blocks) for the complete system.
Before the new batteries are installed, touch up any
nicks, scratches or acid marks on the rack with the paint
provided by the manufacturer. Ensure that the rail
insulators are in good condition or replace. Check that
the rack is level and re-level if necessary. Check the floor
anchors and re-torque all bolts of the rack to
manufacturer’s specifications.
5.4.2 New Racks
Assemble the rack according to the manufacturer’s
instructions. Ensure that the rack is level and all bolts are
properly torqued.
5.4.3 Installation
Determine the location of the positive and negative
terminals of the battery with respect to the rack location.
When placing batteries on the rack, alternate the
polarities for proper intercell connection. Standard
spacing between blocks is 10mm. Position the batteries
on the rack. Do not drop.
5.5 Electrical Connections
Proper battery electrical connections are very important
for the best battery performance and utility. Improper
battery connections can cause a loss of standby time or
even a battery fire. Follow the electrical connection
instructions carefully and review section 2.4 thoroughly
before working on the battery.
CAUTION! Remove all rings and watches before
installing the connectors on the batteries. Ensure that
all tools are insulated with vinyl electrical tape to
prevent shorting. Do not reach or lean across batteries
on step racks. Remember, hazardous voltages are
present. Be aware of what you are touching at all times.
5.5.1 Cabling Recommendations
Battery ratings are specified at the terminals of the
battery. The cabling used to connect the battery
terminals to the load has a voltage drop (when the
battery is discharging) that is dependent on cable length
and conductor size. The longer the cable run, the greater
the voltage-drop. The smaller the cable wire diameter,
the greater the voltage drop. Therefore, to get the best
performance from the battery short, heavy cables are
recommended. Do not size the cables based on current

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carrying capacity only/ A general rule of thumb is to
allow no more than a 30mV of voltage drop/metre of
cable run. As an example, if it is 10m from the battery to
the load, the cable should be sized to allow no more than
2x10x.030 = 0.6V drop. Interblock cables are provided, in
order to help select cable sizes for inter-tier and load
connections, the following table should be consulted:
US Cable Size
Area mm²
Max Amps
30mV Drop/m
8 AWG
8.4
15
6
13.3
23
4
21.2
37
2
33.6
59
1
42.4
74
0
53.5
93
00
67.4
117
000
85.0
148
0000
107.2
187
250 MCM
126.7
221
350 MCM
177.4
309
400 MCM
202.4
353
Use 1.74A/mm² for other cable sizes.
5.5.2 Terminal Preparation
Gently clean the contact surface of the terminals with a
brass bristle brush or a Scotch Brite pad. Immediately
after this cleaning, apply a thin layer of No-Ox-Id ‘A’ or
NCP-2 antioxidant grease to the contact areas. A
petroleum jelly such as ‘Vaseline’ may also be used.
5.5.3 Connector Installation
The VALEN X-CEL Batteries are supplied with hardware to
attach the copper interconnects or cables. Install the
cables (positive of one battery to negative of the next)
and the hardware. Hand tighten only at this time to allow
room for positioning of the blocks. Once all cables are in
place, all connections should be torqued to the values
below:
12 VX 18-33 5.1N-m (45 in pound)
12 VX 44-100 7.4N-m (65 in pound)
12 VX 120-240 11.4N-m (100 in pound)
DO NOT OVER TORQUE.
CAUTION! Use extreme care not to short the battery
connections. VALEN X-CEL Batteries are capable of very
high short circuit currents containing a very high energy
level. Install the inter-tier cabling at this time, following
general instructions as for installing the interblock
connections. Attach the inter-tier cabling to the wall or
the rack so that the weight of the cable is not on the
battery terminal. If using a stiff cable, pre-bend the
cable so no ‘spring’ force is placed on the battery
terminals. Failure to support the cable weight could
result in a premature battery failure and loss of battery
integrity.
5.5.4 Voltage Checks
Visually check that all connections are properly made
(positive to negative) and are tight. Measure the total
string voltage.
CAUTION! High voltage present. The total string voltage
should be approx. 12.5V or 6.25V batteries multiplied by
the number of blocks in the string. If the measured
string voltage is not close to the calculated value,
recheck the battery connections to ensure proper
polarity sequence and measure the individual block
voltages. Calculate the average block voltage and use
this value to refigure the string voltage. If the
recalculated and measured string voltages do not match
reasonably well, contact REGAL ELECTRO for further
instructions.
5.5.5 Battery to Charger Connection
Ensure that the charger is disconnected from the power
line. If a battery disconnect is installed, open it. The
positive terminal of the battery bank should be connected
to the positive terminal of the charger and the negative
terminal of the battery bank should be connected to the
negative terminal of the charger.
5.5.6 Paralleling of Batteries
When greater battery capacity is desired than what is
available from a single cell or string, paralleling of
batteries becomes necessary. Batteries must be properly
paralleled in order to get the best system performance
and longest battery life. The battery strings must be
treated as equally as possible. This means equal length
cabling to a common collection point for the load cables,
uniform temperature between the strings and equal
strings of batteries. Do not parallel flooded batteries with
valve-regulated batteries as the charge voltages differ
between the types of batteries. To check the proper
paralleling of the strings, connect the strings in the final
form and place a load on the battery. Measure the load
cable voltage drops. The voltage drops should match
within 10%.
SECTION 6 - OPERATION
6.1 Initial Charge
REGAL ELECTRO recommends that VALEN X-CEL Batteries
be given an initial charge/equalisation charge at the time
of installation in order to ensure that the batteries are
fully charged and the block voltages are uniform. If an

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initial charge is not given at the time of installation then
block float voltages may take some months to become
uniform. The initial or equalise charge voltage for the
VALEN X-CEL Batteries is 2.35V/cell at 20°C. Calculate the
initial charge voltage for your installation based on either
the number of cells in the string or the number of blocks
in the string. Turn on the charger and raise the charger
output voltage (using the equalisation control) to the
calculated value. Leave the string charging at this level
for 24 hours. At the end of this time, reduce the charger
output voltage to the float voltage level. See section 6.2.
Just prior to reducing the string voltage to the float
voltage, measure the block voltages and charge current if
possible. If the charger output cannot be raised to the
calculated initial charge voltage or the load cannot
tolerate a charge voltage this high, raise the charger
output voltage to the maximum permissible level.
Measure the charger output voltage/cell. Use the
following as a guideline:
Max. Voltage Obtained
(20°C)
Charge Time (hrs)
Min./Max.
2.33-2.35
VPC 12/24
2.31-2.33
VPC 36/48
At voltages below 2.29VPC adequate equalisation will not
be obtained. Contact REGAL ELECTRO for additional
details on procedures to equalise a battery under these
controls. If the ambient temperature is not 20°C, the
initial charge voltage will have to be temperature
compensated (TC). TC is the process whereby the charge
voltage is changed as the function of the battery
temperature. The temperature correction factor (TCF) for
VALEN X-CEL Batteries is -0.005V/C/°C from a 20°C
baseline temperature. As the battery temperature rises
(falls) above (beneath) 20°C the charge voltage must be
reduced (raised) the TCF amount for every degree
change. The formula to calculate the temperature
corrected voltage is:
TCV = CV (20°C) ± [T-20°C] x (-0.005v/c)
As an example, if the initial charge were going to be
performed at 32°C the temperature corrected, reduced,
charge voltage would be:
TCV = 2.35 –(32-20) x (-0.005v/c) = 2.29vpc
6.2 Float Voltage
The float voltage is sometimes known as the continuous
charge voltage. It is very important that it be calculated
and set properly for maximum battery life and
performance. The purpose of the float voltage is to
provide enough float voltage and current to the battery
to compensate for the battery self-discharge and
maintain the battery in a fully charged condition of
readiness. Failure to properly follow float voltage
recommendations can result in loss of warranty and
premature battery failure.
6.2.1 Float Voltage Requirement
The recommended float voltage for the VALEN X-CEL
Batteries is 2.25VPC at 20°C ± 1°C.
6.2.2 Float Voltage Temperature Compensation
The float voltage temperature compensation factor is:
0.005V/cell/°C from at 20°C baseline (the same as the
equalisation TCF). For other temperatures use the
following table.
Temp(°C)
BASELINE
Float Charge
V/C
10
2.290
15
2.270
20
2.250
25
2.250
30
2.230
35
2.210
For temperatures outside of this range see section 6.1 for
the equation used for calculation of the temperature
corrected float voltage.
6.3 Maximum Charge Current
The charge current is normally limited by using the
recommended float voltage at 2.25VPC or 6.75V or
13.5V. At higher charge voltages the maximum charge
current should be limited to prevent the possibility of
charging the batteries at a higher rate than they can
efficiently accept. Greater than recommended maximum
charge currents can result in excessive battery heating
and gassing and a shortened battery life. Maximum
charge rates for VALEN X-CEL batteries; use the 5hour
capacity rate in Amps or 25% of the nominal 20hour rate
in Amps maximum.
6.4 Recharge
Recharge batteries immediately or as soon as possible
after a discharge. Do not wait more than 24hours to
initiate the recharge after the batteries have been
discharged. Failure to follow this recommendation could
result in a permanent loss of capacity due to plate
sulphation. The approx. recharge time can be calculated
as follows:
Ah Discharged
Avail. Charge Current
Where F = 3 if the batteries are charged at the float
voltage and F = 2 if an equalisation voltage is needed. Do
not exceed the maximum charge currents listed in section
6.3.
x F = Charge Time Hr

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6.5 Equalisation Charge
The equalisation charge voltage of the VALEN X-CEL
Battery is 2.35VPC at 20°C. While equalisation is not
required under normal operating conditions, it is possible
to operate the battery in such a way that equalisation
would be needed. These conditions would include:
Temperature variation in the string greater than 3°C
low float voltage
Low operational temperature without temperature
compensation
Frequent deep discharges
Rapid recharge required
Long delay in recharging the battery after a discharge
Unevenly paralleled string balance
Equalisation should be performed on an ‘as needed’
basis. The standard equalisation would be 24hours at
a constant voltage of 2.35VPC at 20°C or 2.33VPC at
25°C. For equalisation at voltages and temperatures
other than the above, see section 6.1 for methods to
compensate.
SECTION 7 - STORAGE
When installed, VALEN X-CEL Batteries will not be used
(floated) for a period of time, the following procedure
should be followed:
1. Equalise charge the battery (refer to section 6.5).
2. Disconnect the battery from all loads. Do not allow any
loads, no matter how small to remain connected.
3. Equalise charge the battery every 6 months when the
storage temperature is 20°C or less. For every 8°C rise in
storage temperature, reduce the storage/equalisation
interval by half.
4. Perform an equalisation charge on the battery prior to
returning to service. During the storage time, particularly
if it is extended, it is recommended to continue to
monitor and record battery voltage levels. Measure and
record the battery open circuit voltage just before
equalisation and then record the on-charge voltage and
current just prior to completing the charge. Refer to
section 4.0 for more information.
SECTION 8 - MAINTENANCE & RECORD-KEEPING
Maintenance and record keeping is critical to battery life
and warranty continuance. Proper maintenance will
ensure that the batteries are being correctly used and will
be available when needed. Proper record keeping will
ensure that, if there is a problem with a battery, the
customer can demonstrate the batteries were correctly
used and so maintain the warranty.
8.1 General Maintenance
General maintenance of the battery means keeping the
battery and surrounding area clean and dry. Since VALN
X-CEL Batteries are of low maintenance design, there is
no addition of water or specific gravity checks needed for
the life of the battery. The only required maintenance
action is an annual re-torque of the battery connections;
see table 1 in section 5.5.1 for re-torque values. Review
section 2.4 on electrical shock before performing this
action.
CAUTION! Use only insulated tools. Do not use any
solvents or strong cleaners on or around the batteries. A
dry brush may be used to remove any dust
accumulations. If required, a solution of 1kg of baking
soda in 4L of water may be used as a multipurpose
cleaner if more stubborn stains or dirt accumulations
are present. Follow the rack or cabinet manufacturer’s
instructions for maintenance if required.
8.2 General Records
8.2.1 Installation Records
When the battery is first received, record:
Date of receipt
Condition of the battery blocks
Open circuit voltage of each block
Date of installation
Original PO number
Installer(s)
Equalisation time and voltage
Any unusual storage conditions
Individual block float voltages
Ambient temperature
Float current
Battery temperature
String float voltage
8.2.2 Maintenance Records
Twice per year, record the following:
Block float voltages
String voltage
Float current
Ambient temperature
Battery temperature
Battery conditions
Any unusual charges or discharges-last 6 months

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INSTRUCTION AND OPERATIONS MANUAL
VALEN X-CEL 6-12V
Keep the above records in a safe place for review by
maintenance personnel. Remember, these records are
mandatory for any warranty claim on the battery.
SECTION 9 - CAPACITY TESTING
9.1 General
Discharge testing of the battery is performed to
determine the battery capacity. There are two reasons
for performing this test:
1. A ratings test discharge –the intention here is to
determine the percent of battery capacity as compared to
the rated capacity. This is typically an 8hour discharge
test.
2. A service test discharge –this test is to determine the
battery standby time under the actual load conditions of
intended battery usage. The ratings test discharge is
usually performed using a suitably designed and sized
load bank to provide a constant DC current load to the
battery. The test is performed for the specified period of
time to an end-point voltage/cell (usually 1.67-1.80VPC)
with the Ah capacity of the battery calculated by
multiplying the load current by the number of hours of
run time. The actual Ah capacity can be compared to the
rated Ah capacity to determine percentage capacity. This
type of test is usually used as an acceptance test of the
battery. The service test is usually performed by placing
the actual load on the battery and determining the actual
time the battery will support the load.
This test is done, in the case of a UPS, by switching into a
test mode where the battery becomes the primary source
and the normal AC line becomes the backup. If the load is
not critical, the AC input can simply be shut off to
simulate a loss of power event and total system
operation can be verified as well. A load bank can be used
if the normal battery load is well defined.
9.2 Test Procedure
The battery test procedure for either test is:
1. Ensure the battery is fully charged before capacity
testing and that all connections are clean and tight. If the
battery has not been on float for at least one week,
perform an equalisation charge, return the battery to
float charge and allow at least 1hour to stabilise.
2. Prepare the load bank or test load system. Ensure all
temporary cable connections are secure and connected to
the proper polarity, and have sufficient current carrying
capacity.
3. Determine the battery temperature by measuring and
recording the temperature of every 6 blocks. Average the
readings to determine average battery temperature.
Measure the battery temperature in the middle of the
side (preferably) or the end wall of the container.
4. If a ratings test is being performed, the load current of
power must be temperature corrected if the battery
temperature is significantly different from 20°C. The
formula for calculating corrected load is:
Temperature Corrected Load = load at 20°C x CF, where
CF is the capacity Correction Factor for temperature.
The following table should be used:
Test Temp (°C)
Capacity Correction
Factor (CF)
0
0.84
5
0.89
10
0.94
15
0.97
20
1.00
25
1.02
30
1.04
35
1.05
If the service test is being performed, no temperature
correction is necessary.
5. Just prior to starting the discharge test, measure and
record the individual block voltages, the string voltage
and float current (if available).
6. Remove or disconnect the charger from the battery
string.
7. Connect the load to the battery and start a timer.
Monitor the string voltage and record the lowest voltage
reached and the time reached (this is called the coup de
fouet and is indicative of a fully charged battery).
8. Record the load current, string and individual cell
voltages on a regular basis. A minimum of three sets of
readings should be taken. The time interval between sets
of readings will vary based on the expected test time. For
example, take readings every hour for the first 4hours of
an 8hour rating test. For the following 3hours take
readings every ½hour. For the last hour, take readings
every 15minutes. For a 15minute UPS discharge, readings
every 1-3minutes would be desirable.
9. Continue the discharge until the string voltage drops
below the end-point voltage/cell times the number of
cells in the string. For example:
1.75VPC x 60cells = 105V-Stop Voltage
10. Stop the timer and remove the load from the battery.
11. Recharge the battery using the existing charger or an
external charger. An equalise voltage may be used to
reduce charge time.
12. Record the discharge time and calculate % capacity of
a ratings test was performed.
13. Keep a copy of all the test data with the battery
records.

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INSTRUCTION AND OPERATIONS MANUAL
VALEN X-CEL 6-12V
9.3 Discharge Test Notes
1. VALEN X-CEL Batteries are shipped at 95% capacity.
Full capacity will be achieved after a few cycles.
2. String voltage should be measured at the battery
terminals, not at the load connections.
3. Accurate metres are essential for correct test results.
Ensure that all metres, shunts, etc. are properly
calibrated before use.
4. If a long duration test is being performed, the terminal-
to-terminal voltage drop across the intercell connections
should be measured and recorded. This will serve as a
reference for any needed terminal maintenance work and
will assist in verifying the battery integrity.
5. A float voltage check after the test and recharge is
recommended.