Testing manual for stationary batteries
Testing manual for stationary batteries
Objective
The presented manual aims to deliver a complete and comprehensive approach to application and testing of PowerBatt for stationary batteries. It shall be interpreted using the support documents attached in the appendix in order to present the client with end-to-end test execution, data analysis and presentation of PowerBatt effects and benefits.
1. Selecting the right product
PowerBatt stationary battery treatment is intended to be used for wet "flooded" type stationary batteries. Treatment is performed using the PowerBatt Prevent product. Application occurs typically every:
· 12 months for batteries which under load more than 20 times per year (frequent power shortages)
· 18-24 months for batteries which are not exposed to frequent power shortages/black-outs<0}
2. Battery selection
Do:
· Select ideally 2 stationary batteries for testing of different age (ideally batteries which are bellow 50% of the typical real-life-span)
· Take batteries from typical conditions (e.g. batteries which are connected to the power back-up system) according to the conditions defined by manufacturer
· Ideally, ask for batteries where there is not too much electrolyte, so that 60ml/100Ah of PowerBatt per cell can be added, but where the maximum levels will not be breached
· Ask for the most recent capacity test results, from the last 2-3 years, to make sure that there are no hidden errors or technical faults
Don’t:
· Don’t consider batteries with mechanical damage (holes, cracks etc.) or bended side walls, or where the positive plate is unusually raised from the battery, which is an indication of internal plate damage
· Don’t take batteries with very low electrolyte level – Electrolyte does not cover the entire plate
· Don’t take batteries which have not been in use for several weeks or months
· Don’t apply PowerBatt, if the residual capacity of the accumulator is at less than 65% of its manufactured capacity
3. Preparation for the test
Do:
· Collect charge-discharge characteristics as specified by the battery manufacturer
· Before the test, make sure the batteries have been in operation before the test
· Ensure the electrolyte level allows for application of 60ml/100Ah of PowerBatt per cell can be added, if there is too much electrolyte, the remove the necessary quantity.
· Ask for the battery use and maintenance instructions to the battery if possible
· It is recommended to take a photo of bended plates before the test (if they are transparent) in order to record the improvement of battery after PowerBatt application
4. Test execution
4.1 Before the test the batteries shall be placed under 3x discharge-charge cycles
4.2 Measure and record the voltage and acid density and ampere-hours in the Test protocol A.3
4.3 Perform the capacity testing in the following manner:
4.3.1 Discharge the battery using standard discharger at a discharge characteristics rate as specified by the battery manufacturer
4.3.2 Record the capacity in the protocol A3
4.4 For each cell add 60ml/100Ah of PowerBatt
4.5 Apply PowerBatt slowly, in order to prevent the battery from sudden chemical overreaction. It is recommended to apply the quantity of PowerBatt in 3-4 instances with 20 minutes in between (In hot climate wait at least 30 minutes). Continuously observe the temperature of the electrolyte, do not add PowerBatt if the temperature of cells rises above 40 degrees Celsius
4.6 Wait for 60minutes, or until the reaction terminates (bubbles are no longer formed violently and the cell temperature begins to decrease)
4.7 Wait until the temperature of cells starts to decrease
4.8 Place the caps on the electrodes
4.9 Charge the battery fully using a standard charger (into operation)
4.10 Make sure that in the following one month the battery will be discharged and fully charged at least once a week
4.11 Perform the capacity testing as specified in point 4.3
5. Test results presentation
· The test results shall be presented to the client in the format of PowerBatt performance report, prepared using the attached guide
· It is recommended to take a photo of the plates after several months (if the plates are transparent in order to record the improvement of battery after PowerBatt application) Attach the photos to the report and protocol
6. Appendix
Test data protocol
Test evaluation preparation guide
Bratislava, March 2013