DATA CENTRE

STANDARD OPERATING
PROCEDURE
BATTERY REPLACEMENT PROCEDURE (UNINTERRUPTIBLE POWER SUPPLY)
1. Document Records
Version Date Description Prepared By Approved By
No.

1.0 8/08/2023 Draft Document

1.1 --/--/2023 Revise Document

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2. TABLE OF CONTENTS

No. Description Page

1. Document Records 1

2. Table of Contents 2

3. Introduction 3

4. Objective 3

5. Work safety, health & Environment 3

6. Quality Control 3

7. Equipment and Tools 3

8. Safe Work Procedure 3

9. Supplementary Information 5

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1. INTRODUCTION

The basic component that differentiates an UPS system from a power conditioner is the battery. If the batteries fail
before the backup generators come on line, the critical power goes down. Improperly installed, poorly maintained,
and inadequately tested batteries are common happenings. In order to make the UPS Battery replacement, inspection
and preventive maintenance shall be conducted regularly. The procedures required for battery replacement must be
defined and carried out by compete person without withstanding the instructions described in this procedure.

2. OBJECTIVE

The main purpose of this standard operating procedure is to stipulate means, measures, responsibility for inspection,
testing and maintenance of UPS, followed by enabling responsible person to carry out battery replacement.

3. WORK SAFETY, HEALTHY AND ENVIRONMENT

a) Safe work procedure

b) Adequate working space, ventilation and luminance
c) Only authorized persons shall supervise the test and handling instruments
d) Ensure all concerned personals use proper PPE.
e) Ensure adequate lighting & ventilation are provided in the working area
f) Conduct Safety briefing

4. QUALITY CONTROL

1. All materials and equipment shall be checked in accordance with specifications

2. Instruments shall be used in accordance with manufacturers’ recommendations
3. Any certified personnel
4. Parts Drawings
5. Manuals

5. EQUIPMENT & TOOLS

Following tools and instruments shall be used for testing or maintenance.

1. Rubber Glove
2. Safety Hat
3. Safety Boot
4. Goggle
5. Screw Driver
6. Spanner box
7. Multimeter
8. Current Tester
9. Other necessary tools

6. SAFE WORK PROCEDURE

Inspection is normally performed by the owner or occupant, or any designated responsible personnel. Maintenance
and recharging shall be performed by competent persons of an approved organization authorized by the relevant

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authority and having available the proper types of tools, recharge materials, lubricants, and manufacturer's
recommended replacement parts.
No Operating Procedure
1 Toolbox Meeting
2 Check Battery
3 Check Environment Condition
4 Visual Check
5 Check electrical parameters
before replace battery (User
Interface)
Description
Appendix
• Check and record the overall float voltage at the battery
terminals (not at the rectifier charger)
• Measure the pilot cell voltage
• Check total battery voltage
• If the battery condition is abnormal, see at content
No. 6
• Check environment temperatures
• Check environment relative humidity
• Check Cleanliness
• Check the date of manufacture
• Check mechanical damage (denting or abrasion)
• Check paint condition
• Check evidence of previous repairs (welding, soldering, brazing,
etc.)
• Make a visual cell and rack check as to general appearance,
cleanliness, cracks in cell, electrolyte leakage, or evidence of
corrosion
• Clean and provide corrosion protection of cells terminals, and
racks
• Provide a detailed visual inspection of each cell
• Check battery terminal connection
• If there is visual inspection is abnormal, see at content No. 6
• Record input voltage, input current, input frequency of each
module.
• Record output voltage, output current, output frequency of each
module.
• Record bypass voltage of each module
• Record and check load percentage and conditions of each
module
• Check and record battery information on UPS monitoring screen
• Make sure no alarm is generated from UPS
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 6 Battery Replacement
(Abnormal Condition)
7 Check electrical parameters
after replace battery (User
Interface)
8 Record
7. SUPPLEMENTARY INFORMATION
No Role
1 Maintenance In-charge
2 Maintenance Engineer
3 Certified workers
• Before replace battery, comply WORK SAFETY, HEALTY AND
ENVIRONMENT at article 3.
• Make sure to change manual bypass mode or brake down the
whole of system (Load size) or switch off the isolated circuit
breaker of battery cabinet.
• When system shut down is not available, need auxiliary power
supply source to load size.
• Make sure to check replaced battery conditions before
replacement.
• If battery is in good condition, no need to make boost charge or
if not, need to make boost charge.
• Check the replaced battery terminal don’t have corrosion
• Remove abnormal battery (remove negative cable before
remove positive cable to preventive electric shock)
• Make sure the positive and negative cable do not touch each
other.
• Check the replaced battery specifications to meet the old battery
• Secure the new battery to the bracket of the cabinet
• Reconnect the positive cable first and the negative cable next
• Scure the battery cable terminal correctly
• Before reactivated the normal operation, ensure system fault
alarm does not occur.
• Upon battery replacement, change manual bypass mode to
normal mode or resume system to normal operation or switch on
the isolated circuit breaker of battery cabinet.
• Record input voltage, input current, input frequency of each
module.
• Record output voltage, output current, output frequency of each
module.
• Record bypass voltage of each module
• Record and check load percentage and conditions of each
module
• Check and record battery information on UPS monitoring screen
• Make sure no alarm is generated from UPS
Check & record the following parameter,
• Date maintenance work was carried out
• Name of person or organization that owns the extinguisher
• Any abnormalities that were found
• Any replacement if carried out
• Analyze records and report any recommendations
No. of person (min:)
1
1
3
5
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