Academy

Battery Installation & Operation Guide

June 2014
Procedure and Parameter settings
 Battery installation procedur
1. Safety Rules
 Working with battery
 Handling of Old Battery
2. Determining Battery Manufacturing Dates
3. Handling
 Do
 Don’t
4. Storage
 Conditions
 Self Discharge During Storage
 Shelf Life
5. Commissioning & Installation
 Unpacking
 Checking the Voltage Spread and Record the OCV and Serial number
 Putting Batteries in Place
 Connecting the Batteries
 Charging the Batteries Prior to Operation
 Boost Charging
 Float Charging
6. Maintenance
 Battery Parameter setting
1. Common parameter
2. Auto Boost / Equalization Parameter
3. LVD 1
4. LVD 2
 Safety Rules
 Read Material Safety Data Sheet at :
http://www.northstarbattery.com/1.0.1.0/189/NorthStar_Battery_Telecom_Installation_and_Operation_Guide.pdf

 Remove batteries which have reached their End Of Life (EOL)

Determaining Battery Manufacturing date
Determaining Battery Manufacturing date
 Battery Handling
DO

 Always use the handles when lifting or carrying a battery

 Always check the OCV (Open Circuit Voltage) before installation

 Always visual inspect the battery before handling it

 If any damage or electrolyte leakage is detected during the

inspection, DO NOT INSTALL THE BATTERY!

 Always follow the instruction provided with the batteries when install them

 Always use insulated tools when handling batteries

 Failure to do so can lead to electric shock and injury to either personnel or
equipment.
 Battery Handling DO
NOT

 Never drag a battery along the floor !

 Never install a battery that has been dropped !

 Never make the final connection to an application until all

batteries in the string have had their interconnection finished !

 Never drill, or in any other way attempt to breach the battery case

 Never force a battery into equipment !

Battery Storage

Condition / List of equipment

Battery Storage
Self Discharge During Storage / Shelf Life

NorthStar batteries have a two year shelf life at +25ºC (+77ºF).

Commisioning
Unpacking the batteries

By Visual check make sure the shipment has no

transportation damage
Batteries packed together in Crate or Pallet
Each battery has a link tied on the handle, since you
need 3 links for a string, you can save one
Use a cutting pliers to cut the tie
Don’t break the black part on the link !!
Checking the voltage spread
 Keep the batteries clean

It’s important to keep the batteries clean, especially the terminal.

There are anti-rust oil on terminal.
If you want to put more oil, make sure it’s conductance oil !!
 Putting the batteries in place

Make sure the batteries are all evenly spaced (about 7 to10 mm), aligned and rest on a
flat surface.
Use always distancer for battery block and temperature sensor
 Battery Label info:

Terminal Torque
Terminal torque of NSB100FT Blue+ is 8 Nm, or
71 in-lb.

Float Voltage
 Read the values from the label.
 Tighten the bolts

The batteries shall be connected into series using the connectors designed for the
particular layout of your delivery
A torque wrench must be used for tightening the bolts on the battery
Please use insulated tools when install batteries.
Installation of last connection and putting back covers

Preferably the last connection should be made at distance from the battery string. If the
system comprises a battery circuit breaker or any other means of disconnection this shall
be in an off condition when connecting the battery to the system.
The covers shall be put back after all connections have been completed.

Batteries Spacer

Battery 3 Temperature Sensor

 Temperature Sensor

It’s very important to install temperature

sensor correctly.
Temp sensor needs to be inserted between
the two central batteries on second top.
Voltage temperature compensation range:0-
45˚C.
High Temperature Alarm:42˚C.
 Keep the Degassing Port Open

Make sure the degassing port is open!!

If the degassing port is blocked, it may cause battery bulging.
 Charging the batteries prior to operation

State of charge vs. Open Circuit Voltage

A full recharged NSB100FT Blue+ has the OCV of about 13.0V
 Charging the batteries prior to operation

Measure the voltage of the batteries

Depending on the voltage of the batteries the batteries might need a charge with a higher
voltage initially

All batteries must be fully charged prior to operation.

The Following table give the charging time requirement to reach full SOC for Blue Star
Technology :
Fast Recharge
Basic Information

Technology: NSB Blue Star TechnologyTM

Nominal Capacity: 100Ah (C/10 to 1.80VPC @25 ˚C)
Nominal Voltage: 12V
Float Voltage: 2.27VPC @25 ˚C
Weight: 35kg
Impedance: 2.6 mΩ
Short Circuit Current: 3500A
Max Charge Current: No limit
Minimum required battery charging current 0,2C10
You can download all the data sheets and all performance tables at:

http://www.northstarbattery.com/downloads/nsbblue/index.php
 Actual Capacity
Lead acid battery’s actual capacity is highly related with ambient temperature, discharge
rate and final voltage
 Battery has higher capacity in higher environment

 Lower rate discharge can get more capacity

 Lower final voltage can get more capacity (Generally 1.80VPC for 10Hours Rate)
 Cyclic Life vs. Depth of Discharge
NorthStar Blue+ battery has excellent cyclic performance.

Lead acid battery’s cyclic life is related to DOD and temperature.

 Thermal Compensation
Charging Voltage at different temperature
Boost: 2.35VPC at 25˚C, temperature coefficient -2mV/cell/C
Float: 2.27VPC at 25˚C, temperature coefficient -2mV/cell/C
What’s the definition of Float Life

 The float life of an AGM battery as a function of temperature follows

the Arrhenius Equation.
 Batteries on float will have a 50% reduction in design life for every increase
of 10ºC (Decrease in life is due to positive grid corrosion).

 The battery at 20ºC will

survive for 12 Years.
 The battery at 30ºC will
survive for 6.5 Years.
 The battery at 40ºC will
survive for 3.5 Years.
 The battery at 50ºC will
survive for less than 02
Years.

The 12 Years, 6.5 Years and 3.5 Years are the float Life of the Battery
What’s the definition of Cycle Life

 By Definition, One Cycle is the sum of 02 Period’s : 01 Discharge + 01 Recharge.

 And is defined as the number of complete charge - discharge cycles a battery can
perform before its nominal capacity falls below 80% of its initial rated capacity. Key
factors affecting cycle life are time t and the number N of charge-discharge cycles
completed
 Total 2000 Cycles, and we are
discharging to 50% DoD and
recharging fully the battery 02
times a day, means :
2000/(2x365) = 2.74 Years.
 If we are doing 30% DoD at the
same temperature, we will have
a total of 4335 Cycles, and we
are discharging to 30% DoD
and recharging fully the battery
02 times a day, means :
3794/(2x365) = 5.19 Years.

The 2.74 Years and 5.93 Years are the Cycle Life of the Battery
What will we consider Float Life or Cycle Life?

 Example :
 The battery at 25ºC will survive
for 12 Years.
 The battery will do at 25ºC, 30% DoD,
02 Times Daily, the Number of Cycles is
3794, The Life Cycle is 5.19 Years.

 The life of the battery considered is 5.19 Years

 The battery at 45ºC will survive for

2.4 Years.
 The battery will do at 45ºC, 30% DoD,
02 Times Daily, the Number of Cycles
is 2168, The Life Cycle is 2.97 Years.

 The life of the battery considered is 2.4 Years

Maintenance
 Batteries Installation check
Site Data        City        
                 
Site Name      Country        
                 
Site ID                
      Item        OK NOK N/A Note
1 Battery installation check               
1.1 Batteries have installed properly and amount of batteries are according to BOQ        
1.2 All connection screw on battery poles are installeds properly and tightened        
1.3 Battery cables connnection have installed properly and secured          
1.4 Plastic covers installed                  
1.5 Gas evaquation tube installed and routed correctly              
1.6 Battery and BCB are lebeled                  
1.7 Battery temperature sensor is installed                
1.8 Batteries are aliegned and have 10mm distance              

2 Battery hardware
                 
2.1 Battery type                  

2.2 Installation date

     
Serial
3 Battery values            
 
Number
  OCV V

3.1 Battery Bank 1-1                    

3.2 Battery Bank 1-2        
3.3 Battery Bank 1-3                    
3.4 Battery Bank 1-4        
3.5 Battery Bank 2-1                    
3.6 Battery Bank 2-2                    
3.7 Battery Bank 2-3                    
3.8 Battery Bank 2-4        
3.9 Battery Bank 3-1                    
3.10 Battery Bank 3-2        
3.11 Battery Bank 3-3                    
3.12 Battery Bank 3-4                    
3.13 Battery Bank 4-1                    
3.14 Battery Bank 4-2                    
3.15 Battery Bank 4-3                    
3.16 Battery Bank 4-4  
                 
Battery Parameter setting : Example for NSB 100FT Blue+
Unstable Grid:
Battery Type : NSB 100FT Blue Plus
Description Values
Capacity Ah /String C10 100
Function “temp. Compensation" Enable
Float voltage V/Cell 2,27
Boost voltage V/Cell 2,35
Equalization voltage V/Cell 2,35
Reference temperature °C 25
Temp. Slope (Compensation) mV/°C/Cell -2
Min. compensation voltage V/Cell 2,22
Max. compensation voltage V/Cell 2,32
Current limit A 0,2 C10
Battery temperature disconnect °C 65
Auto Boost Values
Function "auto Boost" Enable
Max Boost charge time Hrs * 6
Inhibit time ( Time on voltage limit) Hrs * 2
Start Boost charge Cond. 1 Discharged capacity >10%
Stop Boost charge cond. 1 State Of Charge > >99%

Start Boost charge time Cond. 2 Battery charge current >0,1C10

Stop Boost charge Cond. 2 Battery charge current <0,01C10

Auto Equalize Values
Start Equalization Every 2 weeks
Max. Equalization time Hrs 6
LVD 1 (None priority load) Values
Disconnect voltage V/Cell 1,95
LVD 2 ( priority load) Values
Disconnect voltage V/Cell 1,8
Thank You !
(Test 02)
1) Battery Installation & Operation Guide
A) When we are installing a new battery we should:
1) Check the OCV before installation.
2) Check the capacity before installation.
3) Check the current before installation.

B) When installed, each set of 48V battery should have a minimum of :

1) 0.10V between each 12V bloc.
2) 0.15V between each 12V bloc.
3) 0.17V between each 12V bloc.

C) When installed, each 02 Bloc 12V batteries, should have:

1) a minimum distance of : 05mm to 07mm.
2) a minimum distance of : 07mm to 10mm.
3) a minimum distance of : 10mm to 13mm.

D) When we are operation in Boost Charging and high temperature, we should :

1) Decrease the voltage using the compensation ±4mV/Cell/ºC..
2) Decrease the voltage using the compensation ±2mV/Cell/ºC.
3) Increase the voltage using the compensation ±2mV/Cell/ºC.