As we all know, the DC system is primarily composed of a DC charging screen and a battery screen. Among these components, the valve-regulated lead-acid (VRLA) battery pack plays a critical role. In the event of a grid failure, the battery pack serves as the last line of defense by directly supplying power to essential loads. Therefore, maintaining the health and performance of these batteries is crucial for system reliability.
As a manager, how do you effectively monitor and manage these devices? What information do you need on a daily basis? For example: What is the current status of the batteries at each site? Which batteries need replacement this year? Which locations have high maintenance levels? Which manufacturer offers the best quality batteries? Who is responsible for monitoring the maintenance activities? And most importantly, how can you access this information in real-time? How can you generate comprehensive reports? These are key questions that our team has been working on, and they are central to the solutions we aim to provide.
While VRLA batteries offer many advantages, such as low maintenance and long service life, they also come with inherent challenges. For instance, their capacity is difficult to measure accurately, they cannot be refilled with water, and they are sensitive to float voltage settings and environmental conditions. Over time, factors like factory design, equipment quality, float voltage management, and ambient temperature can cause issues such as active material shedding, positive grid corrosion, and sulfation. These problems lead to uneven voltage, reduced capacity, and even complete failure of individual cells, which can create serious safety risks during a power outage.
To address these concerns, the "Maintenance Regulations" require regular capacity testing of battery packs. This helps identify weak or underperforming batteries and ensures the system remains reliable. In practice, we follow a structured approach to battery maintenance, including routine inspections and internal resistance testing. Our "Battery Internal Resistance Tester" is a powerful tool that helps detect backward batteries, measures internal resistance and voltage, and provides an initial estimate of battery capacity—solving the challenge of hard-to-test capacity.
Once a backward battery is identified, it doesn't always mean it's faulty. Many can be restored through proper maintenance. However, due to the nature of battery performance, old and new batteries, or those from different brands or batches, should not be mixed. To address this, we use the "Smart Battery Activator," which effectively restores battery performance and extends its useful life. After regular maintenance and activation, an annual discharge test is conducted using the "Intelligent Discharge Monitor" to accurately assess the battery’s capacity and condition.
In addition to battery maintenance, the impact of the charger on battery health is significant. If the charger’s ripple factor or regulation stability is poor, it can cause overheating, swelling, or even rupture of the battery. While many manufacturers overlook this, we take it seriously. We use a professional instrument called the "DC System Tester" to evaluate the charger’s quality, ensuring that the battery receives stable and safe charging from the very beginning.
Furthermore, according to the "Maintenance Regulations," periodic insulation testing of DC busbars and other equipment is required to assess their insulation status. In case of a fault, the "DC System Ground Fault Finder" quickly identifies the problem location, saving time and reducing downtime.
Beyond the tools mentioned, our company offers a range of specialized instruments designed to support battery testing and maintenance. These tools transform traditional, labor-intensive manual processes into automated data collection using microcontrollers and computers. The B/S structure software enables efficient management of battery stations and groups, allowing managers to monitor battery conditions across all sites from their own computers. The system generates all necessary reports for management, supports decision-making, reduces the workload for technicians, and enhances overall efficiency while ensuring safe and reliable operations.
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KaiPing HuiPu Shower Metalwork Industrial CO,LTD , https://www.hp-shower.com