Tubular IFC & Maintenance

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INSTALLATION AND COMMISSIONING PROCEDURE

FOR

EXIDE TUBULAR TYPE

STANDBY BATTERIES

COMPLETE WITH FIRST CHARGE INSTRUCTIONS AND

MAINTENANCE PRACTICE

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CAUTION :

In order to ensure safety, it is essential to operate and maintain your batteries inaccordance with the recommendations in this booklet.

a) ACID : Batteries contain dilute sulphuric acid which is poisonous andcorrosive. It can cause burns on contact with skin and eyes. If acid is spliton skin or clothing, wash plenty of clean water. If acid gets in to the eyeswash well with plenty of clean water and get IMMEDIATE MEDICALATTENTION.

b) GASES : Batteries can give off explosive gases. Keep sparks, flames andlighted cigarettes away from battery and battery room. Ensure connectionsare tight before switching on, using only insulated tools. Areas wherebatteries are kept or charged must be adequately ventilated.

c) ELECTRICITY: Use only insulated tools to make connections to a battery.Check the circuit to ensure it is safe before making a connection to thebattery. Before working on a battery, always remove personal metal effects,

such as rings, watches, bracelets, necklaces, etc.

ALWAYS PROTECT THE EYES.

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1. Loading / Unloading & handling:The tubular type cells are packed in such a manner so as to avoid rough handlingby the transporter.

Care should be taken during loading / unloading of the cases / pallets on / from thetrucks, preferably with forklifts or suitable mechanical means, without pressure onthe sides, jerk, tilt etc.

2. Storage & Preservation:

The maximum shelf life of dry & uncharged cells is 24 months from the date ofmanufacture, provided the cells are kept as advised below.

The cases / pallets having cells and cases having accessories to be stored in dry &cool covered place, away from direct sunlight and rain. The cells are to be stored insingle layer only. If the dry & uncharged cells are kept loose, adequate care shouldbe taken to keep the Vent Plugs totally closed and the vent holes kept closed withadhesive tapes. They should be kept in a dry cool place avoiding chance ofmechanical damage.

3. Battery Room

The battery room should be well ventilated, clean and dry. A damp room isdangerous due to possible earth leakage from the battery. A notice should be

exhibited in the battery room PROHIBITING SMOKING, ELECTRICAL OR ANYSPARKS AND USE OF NAKED FLAMES. The battery room should be well lit at alltimes of the day and night. Direct sunlight on the cells should be avoided. If it is notpossible to provide windows, good artificial light should be made available.

Although the battery shall have satisfactory performance between 50 C and 500 C,the most preferred operating temperature is between 200 C and 350 C. Highertemperatures shall decrease the life of the cells. Low temperatures, within theabove-mentioned range, will reduce the capacity available but do not harm thebattery so far as the life is concerned. A wash basin is to be provided in the batteryroom, suitably placed for washing of accidental acid splash on eyes, body,

garments etc., for the personnel working in the battery room. Any spillage of acidon the floor is to be washed and neutralised, to avoid leakage path. It is advisableto provide acid proof tiles on the floors and on the sides of the wall. Alternately acidproof paints to be provided which would require periodic renewal.

Proper exhaust fans to be provided to remove hydrogen gas from the battery roomduring boost charging. The ventilation system of the battery room has to bedesigned accordingly. It is always better to pump in filtered cool air in the batteryrooms, having provision for natural exhaust, so that the battery room will be slightlyat higher pressure. The capacity requirement of the exhaust system depends onthe relative size of the battery room and the battery being accommodated in that.

The exhaust calculation can be available from the Guaranteed Technical Particularof the specific installation. Site should demand a copy of the same from theprocurement authority.

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Warning signs should be put on the walls indicating dangers of explosion in usingnaked flames for smoking inside the battery room.

The layout of the cells should be in line with the layout suggested by ExideIndustries Limited for the specific case. For any deviation and / or modification

please contact Exide Industries Ltd.

4. Power Requirement:

A D. C. supply capable of delivering the constant current specified in the technicalspecifications will be required. The voltage required for initial charging is about 3times the number of cells in the battery bank, i.e. charger design to be 3 volts percell. This is required to charge the battery banks e.g. 12 Amps DC ConstantCurrent up to 2.36 vpc & 6 Amps DC Constant Current (finishing rate) up to 2.75vpc per 100 Ah C10 capacity of the battery bank.

5. Stands and Supports

Suitable Stands / Stillages are normally provided for the support of the cells and aredesigned in a manner so that each cell will be easily accessible for inspection,maintenance etc.

Each installation shall have a dedicated relevant layout drawing of the battery. Theyshould be followed very carefully.

6. Charger:

The charging system must be capable of providing a steady voltage within 1%V.

Battery charger should be available at site for necessary initial charging of thebattery bank. This should be a constant current charger capable of supplying 12Amps DC per 100 Ah C10 capacity of the battery to start with and 6 Amps DC per100 Ah C10 capacity of the battery at the finishing stages of charging. The chargershould be capable of providing 6% of the rated capacity of cells at 2.75 volts percell during boost charging. The charger should also have facility for float charge ata voltage of 2.15 to 2.22 volts per cell. For equalizing charge, the charger shall becapable of supplying 3 Amps DC per 100 Ah C10 capacity of the battery.

Charger output or load induced current ripple can cause permanent damageand a reduction in battery life. The RMS limit is 5% in amperes of the C10capacity over the frequency range of 100 Hz to 360 Hz.

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7. Polarity of Charging Leads

It is of utmost importance that the positive terminal of the battery is connected tothe positive lead of the charging source.

To ascertain the polarity of the charging leads connect a lamp in series and dip theend in a glass of slightly saline water. Switch on the supply. Fine bubbles of gas willbe give off from the negative lead

The lamp connected in series eliminates the dangers of accidental short circuits.

8. Acid / DM Water

i) The acid to be used in the battery for initial filling is battery grade

Sulphuric Acid (H2SO4) of specific gravity 1.190 + 0.005, at 270

C,conforming to IS: 266 - 1993. This is normally supplied with the battery. Acopy of IS: 266 1993 is enclosed at the end of the manual.

ii) DM water should conform to IS: 1069 - 1993 for topping up of cells. Acopy of IS: 1069 enclosed.

iii) If the acid is obtained in concentrated form it is necessary to dilute it to 1.190Sp. Gr. The acid as well as the distilled water to be used for diluting theacid should conform to Indian Standard Institution specification IS: 266 1993 & IS: 1069 1993 respectively.

To dilute strong acid, the quantities required for mixing are given below:

For 100 litres Dilute Acid:

Initial Sp. Gravity Final Sp. GravityQuantity of water

in litresQuantity of acid

in litres

1.8401.8251.825

1.400

1.1901.4001.190

1.190

876686

56

184018

45

Note: When acid and water are mixed, there is a volume contraction, hencecolumns 3 & 4 do not total 100.

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+

BULB

HYDROGEN

GAS


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(iv) Caution:

1. All job to be done under supervision of authorised personnel only.

2. Clean vessels of hard rubber, plastics, porcelain or leadlined MS tanks/Wooden Boxes only should be used for storage & handling of acid & DMwater. Do not use metal vessels other than lead.

3. When working with acid or electrolytes always use protective goggles,rubber gloves and rubber apron.

4. Keep ready Bi-carbonate of Soda solution or 5% to 10% Ammonia solutionto take care of accidental spill / splash of acid on skin, eyes or garments.Remove garment immediately, neutralise spot with 5 to 10% ammonia orsoda solution and wash thoroughly in water. On skin / eyes: flush with largequantities of water. Seek medical aid immediately.

5. NEVER ADD WATER TO ACID. IT WILL SPURT DANGEROUSLY.ALWAYS ADD ACID TO WATER. Add the acid in a thin stream, slowly,stirring the solution with a long glass rod or tube.

6. Smoking, Welding Arcs, Electrical Sparks and Open Flame should be strictlyprohibited in the battery room.

7. Only insulated tools should be used for live parts. Extreme care should be

taken while handling of metallic parts within battery room to prevent theiraccidental falling / touching of live parts and causing short circuit.

9. Temperature Correction

The specific gravity of the electrolyte varies with temperature. Any readingobserved on the hydrometer should therefore be corrected to 27 0 C, as allthe specific gravity values indicated by us are at 270 C.The correction should therefore be made as follows:

For every 10

C above 270

C add 0.0007 to the specific gravity as read on thehydrometer. Similarly, for every 10 C below 270 C subtract 0.0007 from thespecific gravity as read from the hydrometer.

10. Installation

The following should be kept in mind while finalising the battery layout:

a) Easy access to the individual cells of the battery

b) Locating the take-offs for easy connection to the charging equipment /

load.

c) Keeping interior connections adjacent to walls for providing easysupport and keeping the passage in between clear. This is desirable

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for easy access to the cells for allowing easy removal of cells forservice attention, whenever required.

d) The positive end of the battery has to be connected to the positiveoutput of the charging equipment and negative end of the battery to

the negative of the charger.

e) The positive and negative take-off of the battery should havesufficient space between them to avoid short circuits

(i) Place the cells in position on the Stand/ Stillage

Suitable insulators should also be used between the stand or Stillage andthe floor. Arrange cells to that the positive terminal lug of one cell adjoins thenegative terminal lug of the next throughout the battery. Use a woodenspacer to ensure even spacing out of cells.

For Seismic stands no Stand/ Stillage Insulator required as these aremechanically fixed to the floor.

(ii) Fasteners (Bolt & Nuts)

Before connecting up, apply an even coating of petroleum jelly to the bolts,nuts, washers, connectors and terminal pillars. Cover the whole length ofeach terminal pillar with petroleum jelly and tighten the bolt connectors firmlyusing two spanners, one on the bolt head and one on the nut.

Note particularly that the positive terminal of one cell is connected tonegative terminal of the next throughout the battery leaving the positiveterminal of the first cell and negative terminal of the last cell of the batterybank free for connection to the charging source. Finally, check again thatthe cells are connected in the correct sequence. Charging a cell of thewhole battery in the wrong direction will cause permanent damage.

(iii) Cells in Rows

If the cells are arranged in more than one row, ensure that the positiveterminal lug of the end cell of one row is connected to the negative terminal

lug of the end cell of the other row. The connection between the two rowsmay be made with the necessary length of copper of the size used betweenthe switchboard and the battery.

Each end of the copper rod/ cable is soldered / crimped into the socket ofthe cable-ends provided or Crimped type Flexible cable connectors, theends of the latter being bolted on the terminal lugs of the battery.

Clean off any flux and bind the exposed end of the cable with self adhesivetape starting well back on the cable insulation and ending just at the flatconnecting lead of the cable socket. Alternately, heat shrinkable PVC tube of

sufficient length to be inserted on the cable before the crimping is done. Thistube will grip the uninsulated end of the cable and cable end when heatedwith a hot air gun and thus will create an insulation layer at that point. All

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copper work should be painted with two coats of acid resisting enamel paintbefore the cells are filled with acid.

(iv) Connecting to charger:

Connect positive terminal of the battery to the positive lead of chargingsource and negative terminal of the battery to negative lead of the chargingsource after identifying the polarity of the connections.

11. INITIAL FILLING-IN OF ELECTROLYTE

Sufficient quantity of battery-grade sulphuric acid and a little spare must beavailable at the site for the initial filling of the cells. The sulphuric acid shouldbe 1.190 +/- 0.005 Sp. Gr. (at 270 C).

The approximate quantity of acid required per cell is given in the data sheet.The total quantity of acid required is obtained by multiplying the quantity percell by the number of cells adding 10% to compensate for spillage.

The acid should be brought to equilibrium with the room temperature and of1.190 Sp. Gravity. This acid should be carefully poured into the cells, up tothe maximum recommended level.

After filling in allow the cells to stand for a period of 8-12 hours. The plateswill absorb the electrolyte and the electrolyte level will drop. Restore theelectrolyte level at the end of this 8-12 hours period by adding more acid of1.190 Sp. Gr.

After filling in all the cells, following are to be ensured prior tocommencement of initial charging: -

a) Checking of correct polarity of all the cells connected in the circuit.

b) Recording of individual cell voltage.

c) Recording the total battery voltage and comparison thereof with the

sum total of individual cell voltage.

The battery is now ready for initial charging.

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12. First Charge

(i) Charging Equipment

Ensure that the charging equipment is in order and is capable of deliveringthe specified current and voltage.

(ii) Connections Polarity

Check and check again to ensure the cells are all connected in series and allfastenings and connections are tight.

Test polarity of the charging leads and connects the positive terminal of thebattery to the positive lead of the charger.

Caution: Charging a cell or battery in the wrong direction will ruin it.

(iii) First Charge

Commence charging not later than 24 hours after filling in the first cell withacid.

(iv) First Portion

The first portion of the charge should be given at any rate between the

starting/ finishing currents depending on the output of the charger. Reducecharging current if temperature of electrolyte exceeds 500 C. Charging at thisrate shall continue till the potential of the battery rises to 2.36 volts per cell.

At the completion of this portion of the charge a rest of not more than 12hour and not less than 2 hours should be given.

(v) Second Portion

The second portion of the charge must be given at the finishing rate asmentioned in the relevant technical particulars. This stage to continue till

either the signs of completion of charge as described in clause 12(vii) areobserved or the minimum Ah input required (as mentioned in the relevanttechnical particulars) is administered, whichever happens later.

This is very important for the life of the battery that the first charge beadministered very particularly so far as the Ah input is concerned.

(vi) Pilot Cells

As pilot cells select any one cell (except the end cell or regulating cell, if any)out of every 24 cells or part thereof.

Voltage and specific gravity readings from the pilot cells will indicate thestate of charge of the whole battery.

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During charge take reading every 4 hourly reading up to 80% of chargefollowed by 1 hourly readings of:

a. Specific Gravityb. Voltage

c. Temperature

(vii) Completion of charge

The signs of the completion of charge are as under

a) Specific Gravity: For some hours after starting the charge,the specific gravity of the electrolyte will fall after which it willbegin to rise slowly and continue to rise throughout the chargeuntil finally it ceases to rise and remain constant. The chargeshould be continued until the specific gravities have attainedconstant figures for three (3) successive hourly readings in allcells.

b) Voltage: The cell Voltage at the beginning of the charge will bea little over 2 volts and will rise during the charge finallyattaining a steady figure. The exact figure is not so importantas long as a Voltage around 2.65 Volts is attained. Typicalfigures range from 2.65 2.75 Volts per cell at the finishingrate of charge, depending on the prevailing electrolytetemperature, which, when higher than 27 Deg C, tends to

depress the voltage slightly from the ideal top of charge of2.75V at 27 Deg C.

c) Gassing: The reduction of current during charge, asmentioned above, is to limit the amount of gassing, but at theend of the charge all the cells should gas freely and vigorously.If any cell fail to gas or is late in gassing or if it s gravity islower than those of other cells, it should be closely examinedto find the cause. When found and corrected the chargeshould be continued until the cell is brought upto the fullycharged state like the others.

When all these signs of completion of charge have been observed, and theminimum Ah input required (as mentioned in clause 12(v)) is administered,the charge should be terminated. About one hour afterwards, when the gasbubbles have cleared away, the specific gravity and temperature should berecorded.

During charging the electrolyte temperature of the cell should not exceed500C. Suspend the charge if the temperature reaches 500 C and resumecharging after the battery has cooled to about 450C. If necessary, slightly

lower the recommended charging rate in case of very high ambienttemperatures. Where ambient temperatures are normally high, it isrecommended that charging be carried out during the night and suspendedduring the day. If necessary, use the finishing rate for the first portion of the

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charge as well. When charging is suspended due to attainment of hightemperatures, such stoppages should be noted carefully and the durationshall be suitably extended to compensate for such stoppages.

(viii) Interruptions

The charging of the battery can be carried out either continuously or incycles of 8 hours charge and not more than 16 hours rest, till it is completed.

(ix) Electrolyte Level

Maintain the level throughout charging adding 1.190 Sp. Gr. Acid ifnecessary.

(x) Adjust Specific Gravity of Each Cell

If at the end of the first charge the specific gravity of the electrolyte exceeds1.205, withdraw some electrolyte and add pure water, continue the chargeso that the water and acid mix thoroughly.

If at the end of first charge the specific gravity of the electrolyte is below1.195 after both voltage and specific gravity have remained constant over 3consecutive hours, withdraw some electrolyte and add acid of 1.400 specificgravity continuing the charge in the meantime.

Never make an adjustment on cell which does not gas on charge.

Final specific gravity should be 1.200 +/- 0.005 in all the cells.

Adjust the levels of electrolyte in all cells by adding 1.200 specific gravityacid or by withdrawing excess electrolyte, as required.

(xi) Final Readings/ Record Book

After correcting specific gravity and electrolyte levels, start a record book forthe whole life of the battery. The first page should record the specific gravityreadings of each cell, and the temperature of the pilot cell, and a note that

levels were correct in each cell. Record details of periodical charges anddischarges etc.

A record book is supplied with each battery of 60 volts and above; forsmaller batteries this can be obtained at nominal charge. If one copy of thisrecord sheet is sent periodically to the nearest office of the Company, freetechnical advice will be given so that the battery is maintained in optimumconditions.

The first charge sheet supplied with the battery should be filled up with thereadings obtained during initial charge and returned to the Company for

comments.

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The Float / Trickle charge should be adjusted to give an optimum batteryvoltage of 2.25 2.27 volts per cell based on the ambient temperature asper the chart given below:

Temperature Float Voltage


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Under normal conditions, the battery should always be in a full state of charge ready for an emergency discharge, and shall be drawing a low steady TrickleCurrent.

The value of the charging current, therefore, gives a rough indication of the state of

charge, if charging voltage is maintained at the recommended float voltage.

Charging voltage:

This is controlled by means of suitable regulators. Under ordinary conditions,voltage should be adjusted between 2.15 to 2.22 volts per cell the exact valuedepending upon the ambient temperature of the installation. When properlyadjusted, the charger shall bring the battery to a fully charged condition promptlyand then furnish only the current to maintain it fully charged. It is, therefore, verynecessary that the voltmeter used is accurate. Any deviation from the standardsetting should be corrected immediately as a very small variation in voltage,produces a large variation in current.

Correct adjustment of the charging rate ensures:

a) Proper amount of charge without applicable overcharge.b) Minimum water consumption.c) Safe limits of operating temperature.d) Prolonged life.

The effect of HIGH and LOW voltage settings are:

HIGH VOLTAGE SETTING:

a) The battery will be overcharged.b) Water requirement will be high and possible fall in the level of electrolyte.c) Temperature will be high which in turn aggravates the condition (a) & (b)

above.d) Life of the battery will be shortened.

LOW VOLTAGE SETTING:

a) Insufficient charge will cause starvation and resultant operating failure.b) Possible damage to the battery due to over-discharge and stoppages for

repairs.c) Shortened life.

Specific gravity is an indication of the state of charge of a battery. In the fully

charged condition, the specific gravity of the battery would read as 1.200 0.005

measured at 27C. A higher specific gravity every time would indicate excessivewater loss possibly due to too high a voltage setting and a lower specific gravitywould indicate that the battery is not receiving sufficient amount of charge. When

temperature of the electrolyte differs from the standard temperature of 27C it isnecessary to correct readings of Specific Gravity observed on the hydrometer to

the equivalent specific gravity at 27C.

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EQUALISING CHARGE:

During the operation of the battery, under constant potential charge, there is achance of imbalance amongst the cells in the bank. This may occur due to various

reasons, e.g. initial differences between individual cells, differences in chargeacceptance, or abnormal working conditions. As a result some cells shall remaincontinually undercharged.

If the Lead Acid cell remains under-charged over long periods, the resultingsulphation in the cells may become so heavy that the cells may go beyond repair.Equalising charge is an extended charge at low Amps, given in order to bring all thecells in the battery bank to a healthy state.

Equalising Charge is to be administered to a battery bank standing on constantcurrent float charging for a long duration and the cell to - cell variation of the float

voltage is of the order of 0.03 volts or the specific gravity variation is of the order

of 0.010. The battery should be charged at a constant current of 3 Amps DC per100 Ah of rated C10 capacity for 12 24 hours. Equalising charge should also beadministered every time the battery is subjected to a C10 capacity discharge.

A NOTE ON WATER LOSS:

Water loss is caused by gassing and evaporation loss, which occurs during later

part of charging; i.e. after the battery reaches about three-fourths of its chargedconditions.

It is therefore; very important that there should be an optimum consumption ofwater since this indicates that a full state of charge is being maintained.

Lower water consumption indicates abnormal conditions; e.g., either a low chargingvoltage or excessive non-emergency discharges in consequence of which thebattery is not being kept in a charged condition. Steps should be taken immediatelyto eliminate the cause of low water consumption.

Water consumption markedly higher than usual suggests that the existence of ahigh charging voltage and this should be checked immediately and adjusted ifnecessary.

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BATTERY MAINTENANCE

Routine maintenance must take account of the following factors and maintainproper record, which are inter-related and are of equal importance:

1. Charging voltage across the battery.2. Specific gravity measurement.3. Water consumption.4. Proper cleaning.

INSPECTION & RECORD:

In order to determine the nature of routine maintenance needed in service, andparticularly the time interval between the inspections, these should be made initiallyat short intervals of a week or so and the results carefully logged and reviewed oneach occasion. Once this experience has been gained, the interval betweeninspections can probably be increased.

The batteries should not be allowed to over-charge. At the same time it should be

ensured that they do not depart from the fully charged condition for the reason thatpartly discharged battery would not be very reliable source of power in case ofemergency.

Systematic inspection programme and carefully kept records of the operation of thebattery and its charging equipment as found at each inspection is one of the best-known methods of controlling battery maintenance. Symptoms of developingtrouble can be quickly detected by regular study of the battery records card andthe necessary corrective measures can be taken in time to prevent any serioustrouble, which might possibly result in a service failure.

The Inspection Register should be kept in a holder located on each Battery Roomso that the desired information can be recorded. Each cell should be marked withan identifying number.

Batteries shall receive regular monthly and annual inspection in addition to anyother attention that the user may desire to give or which may be necessary.

GENERAL INSTRUCTIONS:

a) Do not work on battery bank unless main battery leads are disconnected.

b) Never allow a flame, sparks, lighted pipe or cigarette near the battery.

c) Top up as often as necessary with battery Grade Water conforming to IS1069 (Latest Revision), to keep the electrolyte at the correct level.

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d) Take particular care, avoid short circuit by bridging the terminals withspanner while tightening terminal nuts & bolts.

e) Leave no metal tools on the top of the cells.

f) Take precautions particularly during charging.

g) Give Equalising Charge as recommended, on periodical basis.

h) Do not exceed finishing rate, when cells are gassing freely

i) Keep battery and surroundings clean and dry.

j) Attend to weak cells immediately.

k) If the battery is to stand idle, first give it an equalising charge and if possible,repeat this equalising charge once in 20 days during idle stand.

INSTRUMENTS AND TOOLS

Some important instruments and tools that are necessary for proper maintenanceof battery are listed below: -

a) Digital Multimeter: To enable voltage readings of individualcells as well as total battery and main source voltage. Should becalibrated at regular interval or should be compared with a standardmeter periodically to ensure accuracy.

b) Syringe Hydrometer: A clean and accurate syringehydrometer suitable to read specific gravity readings from 1.100 to1.300 should be used.

c) Thermometer: An accurate thermometer of 0C to 100Crange should be used to read the electrolyte temperature.

d) Tong Tester: To enable readings the current flowing duringcharge, Float and during discharge through the battery and form themain source. Should be calibrated at regular interval or should becompared with a standard meter periodically to ensure accuracy.

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MAINTENANCE SCHEDULE

The maintenance schedule given here is divided in daily, fortnightly, monthly,quarterly, half-yearly and yearly maintenance. The actions to be taken, checks andrecording required are given herewith.

A. DAILY MAINTENANCE

A daily general maintenance should include a check and record of thefollowing :

1. Overall float voltage measured at the battery terminals

2. Charger output current and voltage

3. Specific gravity, voltage and temperature of pilot cells. 2 nos cells outof every 60 cells to be chosen as pilot cells.

B. FORTNIGHTLY MAINTENANCE

A fortnightly maintenance should include all the items mentioned in dailymaintenance and the following :

1. Check voltage, specific gravity and temperature for all cells.

2. Visually check the conditions of each cell and battery bank. Anyabnormality observed to be immediately noted and observed for next15 days.

3. Visually check the cleanliness of battery, battery stands and batteryroom area for accessibility, cell integrity and acid leakage.

C. MONTHLY MAINTENANCE

A monthly maintenance shall include all checks listed under daily andfortnightly maintenance schedule and also the following :

1. Check condition and tightness of all vent plugs and connectors. Cleanall the cells with dry cloth to wipe out any dirt or dust accumulated onthe vent plugs.

2. Check electrolyte level in all the cells and note. Exide tubular cells are

not expected to show much of a water loss in a month but anyabnormal drop in electrolyte level should be noted and cause to beinvestigated.

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D. QUARTERLY MAINTENANCE

A quarterly maintenance shall include all checks listed under daily,

fortnightly and monthly maintenance schedule and also the following :

1. If the specific gravity of most of the cells are found to be lagging by anaverage of 10 to 15 points, the battery bank would call for anequalizing charge at a current equivalent to 3% - 5% of its rated C 10capacity for 6 10 hours to restore the state of charge to full.

2. The temperature of the electrolyte normally is higher than theambient. But for a bank, unless it has undergone a discharge withinprevious 24 hours, the electrolyte temperature should lie within 3 5deg. C higher than the corresponding ambient temperature. In case ofa deviation from this range, the charger needs to be checked for itsquality of power output in terms of the ripple contents in the chargingvoltage and current. Corrective action should be immediately taken toavoid any deterioration in the battery bank due to this anomaly.

3. The voltage and specific gravity data of all the cells from the earlierfortnightly data sheets to be observed. If any cell other than the pilotcells are observed to have different record compared to the othercells in the bank, those cells may be chosen to be the pilot cells for

the next quarter. The pilot cell selection set thus shall be changedevery quarter to ensure rotational attention to all the cells during afixed period of time.

E. HALF YEARLY MAINTENANCE

A half yearly maintenance shall include all checks listed under daily,fortnightly, monthly and quarterly maintenance schedule and also thefollowing :

1. Remove all corrosion product and clean connector thoroughly. Useenough amount of petroleum jelly on the connectors to prevent farthercorrosion and put back shrouds in place.

2. Retighten all the electrical connections between the cells andbetween battery bank and charger to the prescribed torque value.This would ensure proper connection and operation with the minimalloss of electrical energy.

3. The cells, at this point may require topping-up. Fill the cells withbattery grade DM water in such cases where the electrolyte level

indicator fitted on top of the cell indicates that the electrolyte levelinside the cell has reached almost the minimum mark. Do not usemetallic vessel for topping-up as this may contaminate the watetand would run a risk of creating an accidental short circuit.

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F. YEARLY MAINTENANCE

A yearly maintenance should include all items listed under daily, weekly

and monthly maintenance schedule and also the following :

1. Isolate the battery bank from the load. This would require matchingthe annual maintenance schedule with an annual shutdown.

2. The battery bank at this stage is almost at a fully charged condition.After isolation, the bank is to be put on charge in the constant currentmode at a current of 6% of the rated C 10 capacity of the bank ( 6Amps per 100 Ah). The battery bank is to be charged till all the cellsare gassing freely and the voltage and specific gravity readings ofpilot cells have become constant over 3 half hourly reading. Thecharging however should run for a minimum period of 5 hours even ifthe fully charged conditions are achieved before that. The specificgravities and electrolyte levels of all the cells are to be measured andto be adjusted with DM water to specified values 4 hours after thecharging is switched off. The electrolyte level should remain near themaximum mark. After the adjustment the bank is to be charged againfor 1 hour at the same current to enable proper mixing of electrolyteand DM water.

3. After a rest of 12 hours from the time the charging was switched off,

the battery shall be discharged at C10 current for 10 hours. The end ofdischarge voltage at the end of 10 hours is to be noted. Thetemperature and specific gravity readings are to be noted for theentire length of discharge for the pilot cells.

4. The discharged bank should immediately undergo recharge in theconstant current mode. The charging to start at the starting rate asmentioned in the product catalogue for the respective size till the cellvoltage reached 2.36 volts per cell followed by charging at finishingrate pertaining to the specific size of the battery as mentioned inmanufacturers catalogue. The charging to be stopped when the cell

voltage and specific gravity readings are constant for four consecutivehalf hourly readings.

5. The expected end-of-charge voltage is of the order of 2.7 2.75 voltsper cell. During charging it has to be ensured that a minimum Ahinput of 125% of the previous discharged Ah is administered to thebattery. The temperature during charging should not increase beyond450 C. In such cases, the charging to be stopped and the cells to beallowed to cool down till 400 C when the charging can be resumed.The timings are to be noted so that the duration of charge can becompensated accordingly to ensure that the minimum Ah input

requirement is fulfilled.

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6. After the charging is over, specific gravity and electrolyte level of allthe cells are to be adjusted to specified values after 4 hours of restperiod.

7. The battery bank, then, is to be given an equalisation charge at a

current equivalent to 3% - 5% of rated C10 capacity for 16-24 hrs.

8. The battery bank can be given back to the system after the equalisingcharge is over.

EMERGENCY INSPECTION

If battery failure or other difficulty is reported, include the following checks and testsin sequence:

a) Measure total voltage of battery on open circuit and under load. If this isnormal, the actual failure is elsewhere than the battery.

b) Check all battery connections to ensure they are clean and tight.

c) Read and record specific gravity of all cells. If it is low as a whole, the batteryhas discharged. Recharge the battery. Locate the cause and rectify.

d) Read voltage of individual cells at the same time looking for any hot cells orany other abnormal conditions.

If one or more cells are found reading low voltage, read their voltage underload and if it is quite low in comparison with other cells, which is probably theimmediate cause of trouble. Rectify the low voltage cells / Replace withspare Cells to get the battery in service quickly.

SPARE BATTERIES STORAGE AND MAINTENANCE:

a) General care: Spare charged battery should be given regular

good house keeping care. A clean, cool dry place, free from dust anddebris should be selected for storage space. Keep them with ventplugs on.

b) Testing: Spare charged batteries should be checked at regularmonthly intervals to determine the specific gravity. Batteries should becharged before the specific gravity drops 30 points below thespecified fully charged readings. Temperature affects the need forcharges.

b) Charging: When charging is required, use the finishing rate.Continue charging until free gassing occurs. Charging should not be

suspended until specific gravity (corrected for temperature) of majorityof the lowest cells has risen to the maximum and has shown nofurther rise for three consecutive hourly readings.

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ADVICE AND INSPECTION :

It is of utmost importance to Exide Industries that our customers spend worrylesstime whilst using our product. The company is ready to provide all supports andassistance to its valued customers on various issues related to the battery banks inuse. Requests for such assistance should be addressed to the Head Industrialservice & Customer Applications, Exide Industries Limited, 91, New ChordRoad, Athpur- 743 128, Shamnagar, 24 Parganas (North), West Bengal. givingfull details of the battery, inclusive of reference number shown on battery.

Date post:	04-Apr-2018
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