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TECHNICAL MANUAL
CONTENTS
1. Module Specifications - 2
5. K-factor - 18
Page 1 of 23
PRODUCT SPECIFICATIONS
Cell Nominal Module Dimensions Weight Internal Res Short Circuit
Type Capacity Voltage Length Depth Height (Kg+/-5%) of each cell current
(Amp-hr) (Volts) (±10mm) (±10mm) (±10mm) (±5%) m.ohms (±5%) KA
T-80 HP 80Ah 16 778 330 245 63 1.789 1.16
T-100 HP 100Ah 16 778 330 245 71 1.431 1.45
T-120 HP 120Ah 16 778 425 184 91 1.193 1.74
T-160 HP 160Ah 16 778 425 220 120 1.125 1.87
T-200 HP 200Ah 16 778 425 266 137 0.900 2.34
T-240 HP 240Ah 16 778 425 266 157 0.750 2.81
T-280 HP 280Ah 16 778 425 306 160 0.597 3.71
T-320 HP 320Ah 8 778 425 210 110 0.444 4.61
T-360 HP 360Ah 8 778 425 210 124 0.395 5.18
T-400 HP 400Ah 8 778 425 250 135 0.355 5.76
T-440 HP 440Ah 8 778 425 250 149 0.323 6.33
T-500 HP 500Ah 8 778 425 282 169 0.284 7.20
T-520 HP 520Ah 8 778 425 282 169 0.273 7.49
T-560 HP 560Ah 8 778 425 300 186 0.254 8.06
T-600 HP 600Ah 8 778 425 300 194 0.244 8.75
T-680 HP 680Ah 4 778 425 210 124 0.197 10.37
T-760 HP 760Ah 4 778 425 250 135 0.178 11.52
T-850 HP 850Ah 4 778 425 250 149 0.165 12.60
T-920 HP 920Ah 4 452 700 305 168 0.154 13.44
T-1000 HP 1000Ah 4 452 700 305 176 0.142 14.40
T-1100 HP 1100Ah 4 452 700 340 191 0.127 16.68
T-1200 HP 1200Ah 4 452 700 340 210 0.112 18.96
T-1360 HP 1360Ah 4 452 700 420 220 0.099 21.06
T-1440 HP 1440Ah 4 452 700 420 230 0.092 22.11
T-1500 HP 1500Ah 4 452 700 420 240 0.091 22.46
T-1600 HP 1600Ah 2 600 700 300 140 0.084 24.19
T-1700 HP 1700Ah 2 600 700 300 146 0.081 26.25
T-1850 HP 1850Ah 2 452 700 305 168 0.075 28.10
T-2000 HP 2000Ah 2 452 700 305 176 0.068 29.94
T-2200 HP 2200Ah 2 452 700 340 191 0.063 33.31
T-2350 HP 2350Ah 2 452 700 340 210 0.060 35.61
T-2650 HP 2650Ah 2 452 700 420 220 0.052 40.24
T-2800 HP 2800Ah 2 452 700 420 230 0.048 43.05
T-2950 HP 2950Ah 2 452 700 420 240 0.046 45.37
T-3000 HP 3000Ah 2 600 700 290 252 0.045 45.81
T-3225 HP 3225Ah 2 600 700 325 270 0.042 50.43
T-3500 HP 3500Ah 2 600 700 325 285 0.038 56.08
T-3900 HP 3900Ah 2 778 700 290 330 0.032 64.29
T-4200 HP 4200Ah 2 600 700 405 334 0.030 67.03
T-4300 HP 4300Ah 2 778 700 325 353 0.030 67.37
T-4500 HP 4500Ah 2 778 700 325 380 0.029 71.81
T-5000 HP 5000Ah 2 778 700 405 416 0.025 82.92
T-5500 HP 5500Ah 2 778 700 405 432 0.024 87.24
T-5800 HP 5800Ah 2 778 700 405 452 0.023 89.83
* Nominal capacity is at the 10hr. Rate of discharge to an End Cell Voltage of 1.75 VPC at 27°C
* Dimensions given are as per Horizontal stacking alignment.
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VALVE REGULATED LEAD ACID BATTERIES
DISCHARGE CHARACTERISTICS IN AMPERES TO 1.75 ECV*
Page 4 of 23
VALVE REGULATED LEAD ACID BATTERIES
DISCHARGE CHARACTERISTICS IN AMPERES TO 1.80 ECV*
Page 5 of 23
VALVE REGULATED LEAD ACID BATTERIES
DISCHARGE CHARACTERISTICS IN AMPERES TO 1.85 ECV*
Page 6 of 23
VALVE REGULATED LEAD ACID BATTERIES
DISCHARGE CHARACTERISTICS IN AMPERES TO 1.90 ECV*
Page 7 of 23
VALVE REGULATED LEAD ACID BATTERIES
DISCHARGE CHARACTERISTICS IN WATTS
Page 8 of 23
VALVE REGULATED LEAD ACID BATTERIES
DISCHARGE CHARACTERISTICS IN WATTS TO 1.75 ECV*
Page 9 of 23
VALVE REGULATED LEAD ACID BATTERIES
DISCHARGE CHARACTERISTICS IN WATTS TO 1.80 ECV*
Page 10 of 23
VALVE REGULATED LEAD ACID BATTERIES
DISCHARGE CHARACTERISTICS IN WATTS TO 1.85 ECV*
Page 11 of 23
VALVE REGULATED LEAD ACID BATTERIES
DISCHARGE CHARACTERISTICS IN WATTS TO 1.90 ECV*
Page 12 of 23
SELECTING THE RIGHT BATTERY
The selection of the best battery for a certain duty requires some information about the use. Discharge
currents, backup time, operating voltage window and temperature are the basic information necessary
for the correct choice of the battery. Depending upon the duty cycle and the condition under which
the battery is operating, suitable correction factors viz., K-factors, temperature correction factor, end
cell voltage and aging factors are to be used to determine the best techno-economic choice of the
battery for any application.
To give our customers a better service, we have a battery-sizing programme ‘Opti-Size’ using MS-Excel, which
will give the correct techno-economic choice of the battery in no time.
CORRECTION FACTORS
K-Factor: This factor is considered to estimate the available battery capacity at different discharge rates and
end cell voltages. This is the ratio of rated capacity to the amperes that can be supplied for ‘t’ minutes to a
given ECV.
Temperature correction factor: This factor is considered to take care of the variations in performance of the
battery at different temperatures. While high temperatures result in higher performance, lower than nominal
temperatures (27°C) lead to lower performance due to sluggish chemical activity. Temperature correction
factor at different temperatures is given in the table.
Aging factor: IEEE Std 450-1975 recommends that a battery be replaced when its actual capacity drops to 80
percent of its rated capacity; therefore, the battery’s rated capacity should be at least 125 percent of the load
expected at the end of its service life. Hence, a correction factor of 1.25 (=1/0.8) is taken as aging factor.
Design margin: A nominal 10% cushion is taken as a standard over sizing to take care of any design errors in
the loading equipment. This will be considered when specified by the customer.
Over load factor: It is a pure reserve capacity that may be installed to take care of any future additional load.
Normally 10-15% overload factor is considered. This of course will depend upon the customer’s requirement.
This also will be considered only when specified by the user.
TYPES OF LOADS
Common duty cycles imposed on the battery can be classified as (a) Continuous load and (b) Non continuous
loads. Continuous loads are energized throughout the duty cycle whereas non-continuous loads are energized
only in portions of the duty cycle.
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CONTINUOUS LOADS:
Ex.1: Selection of a battery for supplying a load of 10 amps for 5 hours to an end cell voltage of 1.75V when
the system voltage is 48V at an ambient temperature of 27°C.
Step 3: From the K-factor table, for 1.75 ECV and discharge time of 5 hrs, the k-factor is 5.81
Step 5: Applying Ageing Factor of 1.25, Sized battery capacity = 58.1 * 1.25 = 72.63Ah
Step 6: From tables the nearest higher available capacity, 80Ah is chosen. Thus the battery selected is
3 modules (3 modules x 8 cells) of type T80HP
Ex 2: Selection of a battery for supplying 40 KVA load for 30 minutes to an ECV of 1.75 with a Power factor
of 0.8 and an Inverter Efficiency of 85%. The voltage window is 205 – 285V and ambient temperature is -10°C
1. KVA / KW Rating - 40 KVA (Not required when KW rating is given for UPS)
2. Minimum voltage - 205 volt
3. Maximum voltage - 285 volt
4. Power factor - 0.8 (Not required when KW rating is given for UPS)
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5. Efficiency of the Inverter - 85 %
6. End cell voltage - 1.75 volts
7. Operating temperature - -10°C
8. Back up time - 30 minutes
Page 15 of 23
Step 1: Choice of number of cells:
Ensure that the rounded minimum no. of cells is less than the rounded maximum no. of cell. The
number of cells selected should be in between the maximum and minimum number of cells determined
above.
Since both the above min and max voltages are within the UPS voltage window, proceed as below.
Step 3: Power required from the battery (KW / Inverter efficiency) = 32 / 0.85
= 37.647 KW
= 37647 watts
Step 4: Power required from each cell (watts per cell) = 37647 / 120
= 313.73 watts per cell
From the performance table, the Ah capacity of the cell capable of giving 585.49 watts to an end cell voltage of
1.75vpc, as a back up time of 30 minutes is 400 Ah. Battery selected is 30 modules of battery type T400HP.
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NON-CONTINUOUS LOADS (CYCLIC LOADS) :
(Switch gear applications)
Basic terminology:
Load : The current in amperes for each time period
Period : The time during which an applied load is constant and is designated as time M
Section : The basic time unit taken for sizing. The section ‘N’ consists of first ‘N’ periods
K factor : The ratio of rated capacity to the amperes that can be supplied for ‘t’ minutes for a given
ECV and ambient temperature.
Time ‘t’ : The duration between the end of the section and the beginning of each period in every
section.
For sizing, the sequence of each load (in amperes) duration in minutes, system voltage and
temperature are required.
Ex 3: Selection of a battery for a regime having the following load profile for a voltage of 48 volt and
operating temperature of 27°C
Note: 1. Any short period of less than 1 minute duration is considered for 1 minute only.
2. In any section N, if the current for the ‘N+1’ period is higher than the current of the period ‘N’,
then the section ‘N’ may be skipped as the next section ‘N+1’ will be of higher size.
3. Number of cells = Total system voltage / Nominal voltage
= 48 / 2 = 24 cells
Otherwise follow the Step 1 in the Example 2, if voltage window is given.
Step 1 : Fill the load ‘A’ and period ‘M’ values in columns 2 & 4
Step 2 : Fill the changes in load as the difference between the current and previous loads with sign in
column 3
Step 3 : Fill the duration ‘T’ for each period from the beginning to the end of each section in column
5.
Step 4 : Enter the capacity rating factors Kt for each duration ‘T’ in column 6. Refer table number
Step 5 : The cell size for each period ‘P’ is calculated by multiplying column 3 and column 6 and
entered in column 7 with sign convention.
Step 6 : The sum of capacities for all periods in every section is taken as the size of the section.
Step 7 : The maximum value of all the sections noted as above is taken as the uncorrected size.
Thus, the nearest higher available size of 520 Ah (T520HP) is selected. Number of cells selected is 24
nos i.e. (6 modules x 4 cells)
Page 18 of 23
Choose "1" if you want all section values or "0" to hide unnecessary section values 0
1 A1 = A1-0 = M1 = T=M1+M2= =
2 A2 = A2-A1 = M2 = T=M2= =
Sec 2 Total
1 A1 = A1-0 = M1 = T=M1+…M3 = =
2 A2 = A2-A1 = M2 = T=M2+M3 = =
3 A3 = A3-A2 = M3 = T=M3 = =
Sec 3 Total
Page 19 of 23
K-FACTORS
ECV
TIME
1.90 1.85 1.80 1.75 1.70 1.67
Page 20 of 23
Capacity Variation with Temperature
120
110
100
90
Rated Capacity in %
80
70
60
50
40
30
20
10
0
-30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35 40 45 50 55 60
Temperature in °C
Correction Factor 2.083 1.724 1.493 1.351 1.266 1.190 1.136 1.087 1.042 1.010 1.000
Page 21 of 23
Performance Curves at Different Rates of Discharge
2.20
2.15
2.10
2.05
2.00
1.95
1.90
CCV in Volts
1.85
1.80
1.75
1.70
1.65
1.60
1.55
1.50
1 10 100 1000
Time in Hrs
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CHARGING CHARACTERISTICS WITH CP CHARGING
Charge Voltage 2.3 Volts/Cell; Current limit 0.2C10 Amps
120 2.325
110 2.300
2.275
100
2.250
70 2.175
2.150
60
2.125
50 2.100
40 2.075
30 2.050
2.025
20
2.000
10 1.975
0 1.950
0 2 4 6 8 10 12 14 16 18 20 22
TIME IN Hrs
90
80
Capacity Retention %
70
60
50
40
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
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