Published on October 17, 2016
1. TEST PROCEDURE BATTERY CHARGER TEST MECHANICAL CHECK / VISUAL INSPECTION S.no. DESCRIPTION 1. Inspect for physical damage/defects 2. Check nameplate information for correctness as per standards. 3. Check tightness of all external wiring and cabling connections, labeling, drawing pocket shall be checked. 4. Verify all panel mounted devices supplied and installed per approved manufacturer drawings. a. Meters b. Switches c. Push Buttons d. Indicating lamps ELECTRICAL TESTS: S.no. DESCRIPTION 1. Insulation test for all external wiring 2. Battery charger test by simulation of variable load to check for correct charger current output response to different values of load. 3. Check the adjustment range of output float and equalize voltage. Note that the adjustment of float and equalize voltage should be independent of each other. 4. Functional check of the following: Ø High and low output voltages alarm/shutdown. Ø Ground monitoring/ground detector for +ve and –ve alarms. Ø All other protective alarm/shutdown Ø All devices (switches,push buttons, timers, indicating lamps, etc.,) Ø Current limits Ø Soft Start Ø Impedence monitors(if applicable) Ø Silicon droppers(if applicable) Ø Check Output voltage ripple content (battery disconnected) 5. Check regulation at 0%,50%and 100% of full load. 6. Measure AC input and DC output voltages and currents and calculate efficiency at 50% and 100% of rated output current.
2. 7. Calibrate voltmeters and ammeters. 8. If applicable measure the following and verify that they are compatible and meet the requirements of the communications equipment: Ø Voice band noise voltage Ø Wideband noise voltage 9. Check load sharing operation for parallel charges 10. Ensure that the settings of adjusted control, shutdown, alarm voltage, etc., have been reset to the final operational values as specified by the customer. BATTERY TEST Mechanical Check / Visual Inspection S.no Description 1 Inspect for physical damage/defects 2 Check nameplate details for correctness as per standard 3 Check tightness of all external wiring and cabling connections 4 Verify all panel mounted devices (meters, switches .push buttons, indicator lamps,etc.) are supplied and installed according to approved drawings 5 Make sure all battery connections are clean and free from corrosion 6 Verify system configuration and capacity with contract specification 7 Check that all cells are properly numbered 8 9 10. 11. 12. 13. 14. 15. Check protective covers installed Check that all battery maintenance accessories have been provided as per specification. Ensure that all maintenance equipment is stored in a wall mounted lockable cabinet Check that the room ventilation, exhaust fan, etc., are to specification. Check installation of safety equipment (eyewash, showers, No smoking and Warning Caustic/Acid Signs For flooded lead acid batteries , check for correct specific gravity and liquid level Check that all battery racks are correctly and securely grounded Check that the battery bank is provided with an isolating disconnect switch Check that the valve Regulated Lead Acid(VRLA) battery bank has an ammeter provided for monitoring the float charge current
3. Electrical Tests 1 For valve Regulated lead acid batteries, check the open circuit voltage of each cell. 2 Perform initial charging of the battery (equalize voltage, charging rate and charging time according to the manufacturers instruction) 3 Record individual cell voltage electrolyte specific gravity and cell temperatures at the end of charge cycle 4 Battery discharge test: Ø The battery must not have been discharged within last 7 days before test is performed. Ø While battery on float, read and record the voltage of each cell or unit and battery float voltage. Ø Disconnect the battery charger and any other load on the battery. Ø Record the initial voltage of each unit and battery terminals. Ø Select the discharge rate based upon the battery capacity (ampere-hour) and the time period Ø Test shall be carried out for 10 hours. Ø With the variable load bank (dummy load) with an ammeter in series and a voltmeter across the battery terminals, connect the load while simultaneously starting the timing device. Ø Maintain the correct current while periodically reading and recording total battery voltage. Ø After 10 hours record the final unit voltage and compare the test result with the manufacturers recommended voltage chart to confirm the battery end voltage. 5 Fully recharge the battery according to the manufacturer’s instructions.