DC Battery Systems
Corpus sync: neutrality remakes, note hygiene, datasheet relocation, transformer-split cross-refs
Showing changes from Rev 6
to Rev 7
in DC Battery Systems.
---
title: DC Battery Systems
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## Action Submittals {toc}
−### Contractor shall submit the following for the Engineer's review prior to fabrication and procurement.
+### Contractor shall submit the following for the Engineer's review prior to fabrication and procurement:
−### No portion of the DC system shall be ordered or installed before the corresponding submittals are reviewed and returned.
−
−### Contractor shall submit the following action submittals {toc}
- Battery sizing calculation per IEEE 485 (lead-acid) or IEEE 1115 (Ni-Cd), showing the assumed duty cycle, end-of-discharge voltage, design margin, aging factor, and temperature correction factor
- Charger sizing calculation per IEEE 946, showing the assumed continuous DC load, recharge current, and recharge time
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- "Seismic certification for rack and charger"
- "Manufacturer installation instructions"
−default: "Battery sizing calculation (IEEE 485 or IEEE 1115)"
+default:
+ - "Battery sizing calculation (IEEE 485 or IEEE 1115)"
+ - "Charger sizing calculation (IEEE 946)"
+ - "Product data for cells, charger, DC panel, rack, monitor, containment"
+ - "Battery room / cabinet shop drawings with clearances"
+ - "DC system one-line diagram"
+ - "DC cable sizing calculations (ampacity, voltage drop, short-circuit)"
+ - "Ventilation calculation (IEEE 1635)"
+ - "Manufacturer installation instructions"
```
+### No portion of the DC system shall be ordered or installed before the corresponding submittals are reviewed and returned.
+
## Closeout Submittals {toc}
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- "Recommended maintenance schedule (IEEE 450 / 1188 / 1106)"
- "Electrolyte safety data sheet"
−default: "Operation and maintenance manuals (battery, charger, DC panel, monitor)"
+default:
+ - "Operation and maintenance manuals (battery, charger, DC panel, monitor)"
+ - "Acceptance test reports (IEEE 450 / 1188 / 1106), signed"
+ - "Initial commissioning test report (load/performance, charger, alarms)"
+ - "As-built drawings (configuration, cell numbering, polarity, terminations)"
+ - "Baseline record (intercell resistances, float voltages, internal resistance)"
+ - "Warranty documentation (cells and charger)"
+ - "Recommended maintenance schedule (IEEE 450 / 1188 / 1106)"
+ - "Electrolyte safety data sheet"
```
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## Design Ambient Temperature {toc}
+### The design ambient temperature at the battery location shall be as indicated in the datasheet.
+
```datasheet
label: Design Ambient Temperature (Battery Location)
…14 unchanged lines
## Temperature Correction Factor {toc}
+### The minimum battery temperature used in the sizing calculation shall be as indicated in the datasheet.
+
```datasheet
label: Minimum Battery Temperature for Sizing
−type: select
+type: range
unit: °C
options:
− - "25°C (no correction)"
− - "21°C (1.04 multiplier, typical conditioned space minimum)"
− - "15°C (1.11 multiplier)"
− - "10°C (1.19 multiplier)"
− - "5°C (1.25 multiplier)"
− - "0°C (1.30 multiplier)"
−default: "21°C (1.04 multiplier, typical conditioned space minimum)"
+ min: 0
+ max: 25
+ setpoints: [0, 5, 10, 15, 21, 25]
```
+### The temperature correction multipliers associated with the setpoints above are 1.00 at 25°C, 1.04 at 21°C, 1.11 at 15°C, 1.19 at 10°C, 1.25 at 5°C, and 1.30 at 0°C. {note}
+
### The Contractor shall apply a temperature correction factor in the sizing calculation, taken from the cell manufacturer's published data or from the tables in IEEE 485 (for VLA) or IEEE 1115 (for Ni-Cd).
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## Seismic Requirements {toc}
+### The seismic certification basis shall be as indicated in the datasheet.
+
```datasheet
label: Seismic Certification
type: select
+drawing_ref: "structural drawings"
options:
- "Not required"
- "IBC/ASCE 7 — Importance Factor 1.0"
- "IBC/ASCE 7 — Importance Factor 1.5 (essential facility)"
- "OSHPD pre-approval required (California healthcare)"
−default: "Not required"
+default: deferred
```
+### The Seismic Design Category and Importance Factor are established by the project's structural design; the electrical scope adopts them rather than setting them. {note}
+
### Where required by the applicable building code, the battery rack and the charger shall be seismically certified by shake-table testing per ICC ES AC156 or by analysis per ASCE 7.
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## Chemistry {toc}
+### The battery chemistry shall be as indicated in the datasheet.
+
```datasheet
label: Battery Chemistry
…4 unchanged lines
- "Vented nickel-cadmium (Ni-Cd, pocket plate or fiber plate)"
- "Lithium-ion (NFPA 855 / UL 9540 applies)"
−default: "Valve-regulated lead-acid (VRLA, AGM or gel)"
```
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## Nominal Voltage {toc}
+### The nominal DC system voltage shall be as indicated in the datasheet.
+
```datasheet
label: Nominal DC System Voltage
−type: radio
+type: range
unit: VDC
+drawing_ref: "DC system one-line diagram"
options:
− - "24 VDC"
− - "48 VDC"
− - "125 VDC"
− - "250 VDC"
−default: "125 VDC"
+ min: 24
+ max: 250
+ setpoints: [24, 48, 125, 250]
+default: deferred
```
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## End-of-Discharge Voltage {toc}
+### The end-of-discharge voltage per cell shall be as indicated in the datasheet.
+
```datasheet
label: End-of-Discharge Voltage (per cell)
−type: select
+type: range
unit: V/cell
options:
− - "1.75 V/cell (lead-acid, typical short-duration duty)"
− - "1.81 V/cell (lead-acid, longer duty, higher EOD)"
− - "1.67 V/cell (lead-acid, deep discharge, severe duty)"
− - "1.00 V/cell (Ni-Cd, typical)"
− - "1.14 V/cell (Ni-Cd, higher EOD)"
−default: "1.75 V/cell (lead-acid, typical short-duration duty)"
+ min: 1.00
+ max: 1.81
+ setpoints: [1.00, 1.14, 1.67, 1.75, 1.81]
```
+### The setpoints above span both chemistries: 1.00 V/cell (Ni-Cd, conventional) and 1.14 V/cell (Ni-Cd, higher EOD) apply to nickel-cadmium cells, while 1.67 V/cell (lead-acid, deep discharge, severe duty), 1.75 V/cell (lead-acid, short-duration duty), and 1.81 V/cell (lead-acid, longer duty, higher EOD) apply to lead-acid cells. {note}
+
### End-of-discharge (EOD) voltage shall be agreed with the Engineer before sizing, set by the lowest-voltage-tolerant load in the DC system — typically a protective relay, an inverter, or a breaker close coil.
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### The duty cycle is a time-versus-load profile that begins at the loss of charger output and continues through the longest expected period without recharge. {note}
−### The duty cycle shall include three load classes per IEEE 946 {toc}
+### The duty cycle shall include three load classes per IEEE 946:
+
- **Continuous loads** that are present throughout the duty cycle — indicating lamps, relay holding currents, communications power, supervisory relays
- **Noncontinuous loads** energized for a defined portion of the duty cycle — emergency lighting transfers, motor-operated valves, recloser operations, alarm pickup
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### Duty Cycle Duration {toc}
+#### The duty cycle duration shall be as indicated in the datasheet.
+
```datasheet
label: Duty Cycle Duration
−type: select
−drawing_ref: true
+type: range
+unit: hours
+drawing_ref: "DC system duty-cycle diagram"
options:
− - "1 hour (typical attended substation)"
− - "4 hours"
− - "8 hours (typical unattended substation)"
− - "24 hours (remote / isolated site)"
−default: "8 hours (typical unattended substation)"
+ min: 1
+ max: 24
+ setpoints: [1, 4, 8, 24]
+default: deferred
```
+#### The duration setpoints correspond to conventional site types: 1 hour for an attended substation, 8 hours for an unattended substation, and 24 hours for a remote or isolated site. {note}
+
#### The Engineer shall set the duty cycle from the facility's operating concept, not from a table default.
#### Eight hours is the predominant duty cycle for unattended distribution substations because it brackets the time to dispatch a repair crew and restore station service; attended generating stations and stations with redundant station service may use shorter cycles, and remote sites with long restoration times use longer cycles. {note}
−#### The complete time-versus-load duty cycle shall be [[drawing: as indicated on the DC system duty-cycle diagram]].
+#### The time-versus-load profile within the duty cycle shall be [[drawing: as indicated on the DC system duty-cycle diagram]].
## Design Margin {toc}
+### The design margin applied to the sizing calculation shall be as indicated in the datasheet.
+
```datasheet
label: Design Margin
−type: select
+type: range
unit: '%'
options:
− - "10% (minimum, well-defined loads)"
− - "15%"
− - "20% (typical)"
− - "25% (loads not fully developed)"
−default: "15%"
+ min: 10
+ max: 25
+ setpoints: [10, 15, 20, 25]
```
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## Aging Factor {toc}
+### The aging factor applied to the sizing calculation shall be as indicated in the datasheet.
+
```datasheet
label: Aging Factor
…2 unchanged lines
- "1.25 (standard IEEE 485 — sized to 80% of rated capacity at end of life)"
- "1.10 (Ni-Cd per IEEE 1115)"
− - "1.00 (replacement-on-demand strategy — not recommended)"
default: "1.25 (standard IEEE 485 — sized to 80% of rated capacity at end of life)"
```
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## Design Life {toc}
+### The battery design life shall be as indicated in the datasheet.
+
```datasheet
label: Battery Design Life
…5 unchanged lines
- "20 years (VLA, utility station)"
- "20+ years (Ni-Cd, pocket plate)"
−default: "20 years (VLA, utility station)"
```
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## Cells and Monoblocs {toc}
+### The cell or monobloc construction shall be as indicated in the datasheet and shall be consistent with the chemistry selected.
+
```datasheet
label: Cell or Monobloc Construction
…7 unchanged lines
- "Ni-Cd, pocket plate"
- "Ni-Cd, fiber plate / sintered plate"
−default: "VRLA, absorbent glass mat (AGM)"
```
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## Charger Sizing {toc}
+### The charger sizing basis shall be as indicated in the datasheet.
+
```datasheet
label: Charger Sizing Basis
…19 unchanged lines
## Charger Output Voltage Modes {toc}
+### The charger output voltage modes shall be as indicated in the datasheet.
+
```datasheet
label: Charger Output Modes
type: select
options:
− - "Float only"
+ - "Float without equalize"
- "Float and equalize (manual initiation)"
- "Float and equalize (automatic, time-initiated)"
− - "Two-rate float (temperature-compensated only)"
+ - "Two-rate float with temperature compensation"
default: "Float and equalize (manual initiation)"
```
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## Charger Redundancy {toc}
+### The charger redundancy arrangement shall be as indicated in the datasheet.
+
```datasheet
label: Charger Redundancy
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## Charger Output Filtering and Ripple {toc}
+### The maximum AC ripple at the charger output shall be as indicated in the datasheet.
+
```datasheet
label: Maximum AC Ripple at Charger Output
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## Charger Alarms and Indications {toc}
−### The charger shall provide, as a minimum, the following alarms and indications, wired to dry contacts available at a terminal block for connection to the facility's annunciator or SCADA {toc}
+### The charger shall provide, as a minimum, the following alarms and indications, wired to dry contacts available at a terminal block for connection to the facility's annunciator or SCADA:
+
- AC input loss
- High DC voltage
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- Battery on discharge (current flowing out of the battery)
+### The alarms reported to the annunciator or SCADA shall be as indicated in the datasheet.
+
```datasheet
label: Charger Alarms to SCADA / Annunciator
…9 unchanged lines
- "Charger in equalize"
- "High battery temperature"
−default: "AC input loss"
+default:
+ - "AC input loss"
+ - "High DC voltage"
+ - "Low DC voltage"
+ - "Ground fault — positive bus"
+ - "Ground fault — negative bus"
+ - "Charger fail"
+ - "Battery on discharge"
```
…4 unchanged lines
## DC Panel Configuration {toc}
+### The DC distribution panel configuration shall be as indicated in the datasheet.
+
```datasheet
label: DC Distribution Panel Configuration
type: select
+drawing_ref: "DC system one-line diagram"
options:
- "Single bus, single charger, single battery"
- "Single bus, redundant chargers, single battery"
- "Dual bus with tie, redundant chargers, single battery"
- "Dual bus, fully redundant (two chargers, two batteries)"
−default: "Single bus, single charger, single battery"
+default: deferred
```
…4 unchanged lines
## DC Overcurrent Protection {toc}
+### The DC branch overcurrent protection type shall be as indicated in the datasheet.
+
```datasheet
label: DC Branch Protection
…18 unchanged lines
## Battery Disconnect {toc}
+### The battery disconnecting means shall be as indicated in the datasheet.
+
```datasheet
label: Battery Disconnect
…12 unchanged lines
## System Grounding {toc}
+### The DC system grounding method shall be as indicated in the datasheet.
+
```datasheet
label: DC System Grounding
…18 unchanged lines
# Battery Monitoring {toc}
+## The battery monitoring capability shall be as indicated in the datasheet.
+
```datasheet
label: Battery Monitoring System
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## Ventilation Method {toc}
+### The battery space ventilation method shall be as indicated in the datasheet.
+
```datasheet
label: Battery Space Ventilation
…3 unchanged lines
- "Continuous mechanical ventilation"
- "Mechanical ventilation initiated by hydrogen detector"
− - "Sealed cabinet with internal recombination (small VRLA only)"
+ - "Sealed cabinet with internal recombination (small VRLA installations)"
default: "Continuous mechanical ventilation"
```
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## Ventilation Rate {toc}
+### The mechanical ventilation rate shall be as indicated in the datasheet.
+
```datasheet
label: Mechanical Ventilation Rate
…13 unchanged lines
## Hydrogen Detection {toc}
+### The hydrogen detection provisions shall be as indicated in the datasheet.
+
```datasheet
label: Hydrogen Detector
…14 unchanged lines
## Room Construction {toc}
+### The form of battery housing shall be as indicated in the datasheet.
+
```datasheet
−label: Battery Room / Cabinet Location
+label: Battery Housing Type
type: select
options:
…3 unchanged lines
- "Outdoor cabinet adjacent to switchgear"
- "Indoor cabinet within electrical room"
−default: "Dedicated battery room within electrical room"
```
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# Spill Containment {toc}
+## The spill containment method shall be as indicated in the datasheet.
+
```datasheet
label: Spill Containment Method
type: select
options:
+ - "Not required — VRLA, no free electrolyte"
- "Built-up curb with sealed, electrolyte-resistant floor coating"
- "Drip pans under each cell row, drained to neutralization sump"
- "Modular containment trays integral to the rack"
− - "Not required — VRLA, no free electrolyte"
−default: "Modular containment trays integral to the rack"
```
+## A VRLA installation has no free electrolyte to contain and records "Not required" rather than leaving the field ambiguous. {note}
+
## VLA and vented Ni-Cd installations contain free liquid electrolyte and shall be provided with spill containment per IEEE 1578 and the applicable building and fire codes.
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## Labeling {toc}
−### Permanent, durable labels shall be applied to the battery, the charger, the DC distribution panel, and the battery disconnect, identifying the following {toc}
+### Permanent, durable labels shall be applied to the battery, the charger, the DC distribution panel, and the battery disconnect, identifying the following:
+
- The system designation (e.g., "125 VDC Station Battery No. 1")
- The nominal voltage and the ampere-hour rating
…9 unchanged lines
## Factory Tests {toc}
+### The extent of factory acceptance testing shall be as indicated in the datasheet.
+
```datasheet
label: Factory Acceptance Test
…2 unchanged lines
- "Witnessed factory capacity test (complete battery)"
- "Unwitnessed factory capacity test with certified report"
− - "Cell-level certificate of conformance only (no complete battery test)"
−default: "Cell-level certificate of conformance only (no complete battery test)"
+ - "Cell-level certificate of conformance (no complete battery test)"
+default: "Cell-level certificate of conformance (no complete battery test)"
```
…10 unchanged lines
### Field acceptance testing shall occur after installation and initial charging are complete and before the battery is placed in service.
−### Field acceptance tests shall include as a minimum the following {toc}
+### Field acceptance tests shall include as a minimum the following:
+
- Visual inspection of every cell, the rack, the intercell connectors, and the spill containment
- Measurement and recording of total float voltage and current
…5 unchanged lines
- Battery monitor functional test, including alarm and trend verification
+### The acceptance capacity test shall be as indicated in the datasheet.
+
```datasheet
label: Acceptance Capacity Test
…3 unchanged lines
- "Modified performance test (combined performance and service test)"
- "Service test (project duty cycle at the project EOD)"
− - "Not required at acceptance — periodic test only after warranty"
+ - "Not required at acceptance — periodic capacity testing begins after the warranty period"
default: "Performance test (full duty cycle to EOD voltage)"
```
−### The Engineer shall not waive the acceptance capacity test on the grounds of cost.
+### The acceptance capacity test shall not be waived during construction on the grounds of cost; where no acceptance test is performed, the omission shall be a documented design decision recorded in the datasheet.
### A performance test or modified performance test at acceptance establishes the as-installed capacity of the battery and is the baseline against which all future performance is judged; IEEE 450, IEEE 1188, and IEEE 1106 each describe the corresponding test for their chemistries, and a battery whose installed capacity was never measured cannot be defended at any later point in its life. {note}
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## Maintenance Intervals {toc}
+
### The following maintenance intervals are representative and shall be tailored to the installation by the Owner:
- **Monthly** — total float voltage, total float current (where measured), ambient temperature, visual inspection for leaks or unusual conditions, electrolyte level (VLA), pilot cell specific gravity (VLA)
…11 unchanged lines
# Warranty {toc}
+## The cell or monobloc warranty shall be as indicated in the datasheet.
+
```datasheet
label: Cell / Monobloc Warranty
…3 unchanged lines
- "2 year full / 18 year prorated (long-life VRLA)"
- "2 year full / 18 year prorated (VLA)"
− - "Manufacturer's standard for Ni-Cd"
−default: "2 year full / 18 year prorated (VLA)"
+ - "2 year full / 20 year prorated (Ni-Cd)"
```
+## The charger warranty shall be as indicated in the datasheet.
+
```datasheet
label: Charger Warranty
…18 unchanged lines
# Spare Parts and Tools {toc}
+## Spare parts and tools shall be furnished as indicated in the datasheet.
+
```datasheet
label: Spare Parts to be Provided
…7 unchanged lines
- "Calibrated torque wrench for intercell connections"
- "Cell-handling lifter (where cells exceed 50 lb)"
−default: "Spill kit (one per battery room)"
+default:
+ - "Spare intercell connectors and hardware (10% of installed quantity)"
+ - "Spare DC fuses (one set of each rating installed)"
+ - "Spill kit (one per battery room)"
+ - "Calibrated torque wrench for intercell connections"
```
## Spare cells, where provided, shall be stored on a level surface, kept in float charge or freshened on the manufacturer's recommended interval, and labeled with the installation-ready date.
## A spare cell that has been allowed to sit on the shelf for years without freshening is not a spare; it is a failed cell that the Owner does not yet know is failed. {note}