Battery Maint & Handling Doc - EA
Battery Maint & Handling Doc - EA
Battery Maint & Handling Doc - EA
ABOUT SABAL
Sabal includes a highly optimized, innovative electric tandem-rotor unmanned
helicopter design for high efficiency of the larger rotor size of the helicopter with
the excellent load-carrying ability of the tandem rotor helicopter configuration
with a variable-speed electric propulsion system to compensate for the reduction
in density by increasing rotor rpm and variable blade pitch.
Sabal 10 & 20 is rotor tandem UAV with electric propulsion system engineered for
unparalleled efficiency, with vertical take-off and landing capabilities while
ensuring optimal performance and endurance even in adverse weather
conditions.
It is a game-changing logistics drone weighing under 40 to 60 kg with a 10 to 20 kg
payload. The design has been inspired by the Boeing Chinook. Crafted with 65%
indigenous components, it embodies India’s innovation at its core.
Lithium- Ion Batteries are used in delivery drones to deliver the consumer needs. Hence battery
capacity is decided based on payload weight
In our Sabal Drones we have used the QS 80C and XT 90 connector plugs to charge the battery
1. Manuals begin by thoroughly reviewing the manufacturer's guide specific to your battery and
device. Understand the recommended procedures, safety precautions, and any specific
instructions provided.
2. Start by reading the manual for your specific flight battery and drone before flying.
Understand the basic functionality, especially the section on Intelligent Flight Batteries.
3. Always fly with a fully charged battery securely mounted in your aircraft. Before flight, ensure
batteries are properly fitted and charged to 100% as part of your pre-flight checklist.
4. Never install or remove a battery from your drone when it’s turned on.
6. Adhere to the operating temperature guidelines in your drone user manual. Cold
temperatures reduce battery capacity, while warm temperatures may lead to irreversible
battery failure.
8. Every 20 cycles, fully charge and discharge your aircraft’s battery to optimize its lifespan.
Unlike older LiPo batteries, this practice won’t cause lasting damage if done sparingly.
9. Keep battery, charger, and aircraft connectors clean from debris and dust. Use a clean, dry
cloth or compressed air canister for cleaning. Avoid sharp or metal objects that could cause
damage or short circuits.
10.If you encounter a battery error, try fully discharging the battery then recharging. Unlike
older LiPo batteries, Intelligent Flight Batteries retain some charge to prevent irreversible errors
during discharge.
1. Gathering the necessary equipment- Gather the necessary equipment like a Battery
Charger, Power Cable, one 6S-12S board for connecting the battery. In Sabal drones we
are using 12S 30Ah Mpower battery setup for charging the battery
2. Prepare The Work Area- Make sure charging area is dry clean and well-ventilated area
since the battery on charging gets heated it can help to reduce the surrounding
temperature of the battery, non-flammable. Avoid charging near carpets or cloth
3. Connect the Battery- To avoid short circuits between the plugs, always connect the
charge leads to the charger first, and only then to the battery. Reverse the sequence
when disconnecting the pack. The balance wire and the main port attached to the
battery must be connected to the charger with black wire aligned with the negative
marking. Ensure correct polarity
4. Set the parameters – These steps outline the proper procedure for connecting,
selecting modes, and starting the charging process using the UP1200 Plus battery
charger
a. Connect the power cable to the AC input and then press the power switch to turn on
the battery charger.
b. The battery has two connection lines: one with a QS-80 S connector attached to red
and black cables, and the other with a black-colored power cable. The battery
charger has XT 90 ports.
c. After ensuring all connections are secure, press the Start/Stop button to initiate the
battery charger.
d. On the UP1200 Plus charger, select the charging mode. There are two modes
available:
- Charge Mode: Use this mode for continuous battery use. It charges the battery to
its full capacity.
- Storage Mode: Choose this mode when the battery won't be used continuously. It
helps maintain the battery in good condition during extended periods of storage.
e. To select the Charge Mode:
- Press the 'Select' button.
- Choose the desired charging current (typically between 10 to 15 Amps).
- Press 'Select' again to confirm and start the charging process.
f. Your charging process will now commence.
5.
Figure 1 Labelled Diagram of Charger
Figure 2 Front View Battery Charger
1 Unit of Ultra Power UP1200AC PLUS 1 Power Cable 2 Unit of 6S-12S Board
2X600W 15A 6-12S Battery Balance Charger
Battery Discharging:
Important steps to remember before discharging Li-Ion battery for longevity and safe
operation.
Avoid Full Discharge: Don’t discharge Li-Ion batteries fully before recharging. In fact,
deep discharges can be harmful to Li-ion batteries and reduce their lifespan. So, it’s
recommended to avoid letting the battery level drop to 0% if possible.
Use Moderate Discharge levels: These batteries will give good efficiency when they
charged from moderate level, so always discharge your batteries up to 20% - 30% and
then recharge it.
Use Manufacture Recommendations: Follow manufacturer guidelines and instructions
to maximize battery life and safety.
Monitor Battery Usage: Don’t discharge and charge a single battery multiple times a day
and note down its cycles.
Voltage Check
Voltage is checked using multimeter steps you should follow while checking the battery voltage
To check the voltage of a drone, start by ensuring the drone is turned off. Locate the battery,
which may require removing a cover or compartment. You'll need a multimeter set to measure
DC voltage. Connect the red probe to the positive terminal and the black probe to the negative
terminal of the battery.
The multimeter will display the battery's voltage, which varies depending on the drone model
and battery type (e.g., 3.7V for Lio batteries). Always prioritize safety when handling electrical
components and seek assistance if uncertain about the process.
Installation of Battery
1.To properly install a battery in a drone, begin by ensuring the drone is powered off completely
to avoid inadvertent activation. Locate the designated battery compartment, typically situated
on the underside or within the drone’s body structure. Prior to installation, verify the battery's
charge status to ensure optimal performance.
2.Position the battery within the compartment according to the manufacturer's specified
orientation, typically indicated by clearly marked indicators. Secure the battery using the
appropriate securing mechanism provided, such as a latch or strap, adhering closely to the
manufacturer's recommended installation procedures.
3.If the drone features a removable battery pack, carefully connect the battery's designated
connector to the corresponding power port within the drone. Confirm the connection is secure
and stable before proceeding.
4.Once installed, power on the drone following the prescribed startup sequence outlined in the
manufacturer’s guidelines. Verify operational functionality and confirm that the drone initializes
correctly. Monitor battery status indicators, often displayed via remote control or companion
app, to ensure accurate power level readings.
5.Exercise utmost caution when handling drone batteries, particularly those utilizing Lithium Ion
(Li-Io) technology. Adhere strictly to safety protocols during all phases of battery management,
including storage, charging, and handling, to mitigate potential risks associated with high-
energy density batteries.
By adhering to these procedures, one can effectively and safely install a battery in a drone,
optimizing performance and ensuring operational readiness
Battery Usage
Regular Inspection
1. Visual Inspection
-Check for any physical damage to the battery casing, such as cracks or bulges. Damaged
batteries should not be used as they can pose safety risks.
-Ensure that the connectors and terminals are clean and free from debris. Dirty
connectors can affect the battery’s performance and connection stability. Make sure all
connectors and battery plugs are rust free
-Keeping a flight log for your drone helps you track how long you've been using it. This is
important because drone batteries, which are often made from lithium-ion, don't last
forever. Even if you don't use them much, they can wear out over time.
If you notice any abnormalities, discontinue use immediately and report the issue to us.
Storage
1. Battery Mode:
If you’re not using the battery for a long period, then charge the battery in
storage mode and check voltages are in nominal and keep it aside.
2. Storage Place:
-Store the batteries in dry and ambient temperature places and avoid heat
sources such as radiators, heaters, or direct sunlight. High temperatures can
accelerate battery degradation.
3. Avoid Full Discharge:
-Regularly check the voltages of the lion battery and charge them to nominal
voltage. Avoid storing fully discharged batteries, as this can lead to irreversible
capacity loss or even damage.
4. Packaging:
-Store the battery in original packaging with safety to protect against physical
damage and short circuits.
5. Monitoring: -
- Periodically inspect stored Li-ion batteries for any signs of physical damage,
leakage, or swelling. If you notice any abnormalities, handle them with caution
and dispose of them.
Emergency Response
1. Local Regulations
- Check the local guidelines to Dispose the hazardous material because
every area has their own regulations.
2. Discharge Battery
- If possible, try to discharge the full battery and try to cut the leads as close
to the battery as this will help us in reducing the risk of recharging and short
circuiting.
3. Recycling Options
- Many communities have recycling programs or drop-off locations for
hazardous materials. Contact local recycling centers, electronics stores, or
municipal waste management authorities to inquire about battery recycling
options.
4. Dispose in Household Waste
- Never dispose of the battery in Household waste, because there is a high
chance of causing fire due to the chemicals and metals they contain.
5. Manufacturer Guidelines
- Some manufacturers or retailers provide specific instructions or collection
points for recycling their products and batteries. Check the product manual
or their website for guidance.
6. Battery Packing
- If possible, package the Li-ion battery in its original packaging or use
insulated materials to prevent physical damage and label them as “Used” or
“To Be Recycled” to indicate its dispose status.