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Exide Battery O &M Manual PDF
Exide Battery O &M Manual PDF
FOR
STANDBY BATTERIES
MAINTENANCE PRACTICE
-1-
GENERAL :
b) GASES : Batteries can give off explosive gases. Keep sparks, flames and
lighted cigarettes away from battery and battery room. Ensure connections
are tight before switching on, using only insulated tools. Areas where
batteries are kept or charged must be adequately ventilated.
-2-
1. Loading / Unloading & handling:
The Plante type cells are packed in such a manner so as to avoid rough handling
by the transporter.
Care should be taken during loading / unloading of the cases / pallets on / from the
trucks, preferably with forklifts or suitable mechanical means, without pressure on
the sides, jerk, tilt etc.
The maximum shelf life of dry & uncharged cells is 24 months from the date of
manufacture, 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
in single layer only. If the dry & uncharged cells are kept loose, adequate care
should be taken to keep the Vent Plugs totally closed and the vent holes kept
closed with adhesive tapes. They should be kept in a dry cool place avoiding
chance of mechanical damage.
3. Unpacking / Handling:
Care should be taken in the unpacking and subsequent handling of cells and other
components of the battery.
It is advisable to unpack all the cases and crates as soon as possible upon arrival
at site It is preferable to unpack all the materials supplied in one go for checking
correctness of materials quantity wise and quality wise before erection rather than
going for unpacking and erection cell by cell.
It is advisable to carry the packed cells in crate pallet upto the Battery Room floor
by overhead crane. The pallets are designed for lifting with sling wires, care should
be taken to avoid pressure on the sides of the crate pallet, to avoid damage. The
crates should be opened in the battery room floor and shifted to the battery room
with care. Never handle cells using the terminals as this might create fatal
damage to the cells.
To open the crate pallet, cut the hoop iron straps and lift the outer part of the crate
from the top. Then cut the hoop iron straps of the inner crate and dismantle the
crate carefully by using crowbar / hammers etc, to avoid damages. Take out the
cells one by one manually. Care should be taken in handling the cells and other
components to avoid damages. The cells to be shifted to battery room by
convenient way ensuring no damages during such handling. Unpack and check all
items carefully against the accompanying delivery challan / material specifications.
Report shortages/ damages promptly to Exide Industries Limited in writing within 30
days of receipt. Free replacement would only be entertained if such reports are
received within the stipulated time period, provided the transit insurance is covered
by the Company. Arrange for repairs/ replacement of damaged/ short received
materials to ensure the complete battery material is available when installation
commences.
-3-
Store the cells (with the vent plugs & vent-cum float guide, screwed on firmly), and
other accessories in a dry cool, dust fee covered place.
3. Battery Room
The battery room should be well ventilated, clean and dry. A damp room is
dangerous due to possible earth leakage from the battery. The floor and walls of
the battery room should preferably have acid resistant coating. A notice should be
exhibited in the battery room PROHIBITING SMOKING, ELECTRICAL OR ANY
SPARKS AND USE OF NAKED FLAMES. The battery room should be well lit at all
times of the day and night. Direct sunlight on the cells should be avoided. If it is not
possible to provide windows, good artificial light should be made available.
The battery will give the best results when working at room temperatures of 250 C to
350 C. It will function satisfactorily when operating at temperatures between 50 C
and 500 C. High temperatures increase the capacity but decrease the life of the
cells. Low temperatures, within the above mentioned range, will reduce the capacity
available but do not harm the battery so far as the life is concerned. A wash basin
to be provided in the battery room, suitably placed for washing of accidental acid
splash on eyes, body, garments etc., for the personnel working in the battery room.
Any spillage of acid on the floor is to be washed and neutralised, to avoid leakage
path. It is advisable to provide acid proof tiles on the floors and on the sides of the
wall. Alternately acid proof paints to be provided which would automatically require
periodic renewal.
Proper exhaust fans to be provided to remove hydrogen gas from the battery room
during boost charging. The ventilation system of the battery room has to be
designed accordingly. It is always better to pump in filtered cool air in the battery
rooms, having provision for natural exhaust, so that the battery room will be slightly
at higher pressure. The capacity requirement of the exhaust system depends on
the relative size of the battery room and the battery being accommodated in that.
The exhaust calculation can be available from the Guaranteed Technical Particular
of the specific installation. Site should demand a copy of the same from the
procurement authority.
Warning signs should be put on the walls indicating dangers of explosion in using
naked flames for smoking inside the battery room.
The layout of the cells should be in line with the layout suggested by Exide
Industries Limited for the specific case. For any deviation and / or modification
please contact Exide Industries Ltd.
4. Power Requirement:
-4-
5. Stands and Supports
Suitable Stands / Stillages are normally provided for the support of the cells and
are designed 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. They
should 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 the
battery bank. This should be a constant current charger capable of supplying 12
Amps DC for 100 Ah battery to start with and 6 Amps DC for 100 Ah battery at the
finishing stages of charging. The charger should be capable of providing 6% of the
rated capacity of cells at 2.75 volts per cell during boost charging. The charger
should also have facility for float charge at a voltage of 2.25 + 0.02 volts per cell.
For equalizing charge, the charger shall be capable of supplying 3 Amps DC per
100 Ah battery.
Charger output or load induced current ripple can cause permanent damage
and a reduction in battery life. The RMS limit is 5% in amperes of the C10
capacity over the frequency range of 100 Hz to 360 Hz.
To ascertain the polarity of the charging leads connect a lamp in series and dip the
end in a glass of slightly saline water. Switch on the supply. Fine bubbles of gas will
be give off from the negative lead
The lamp connected in series eliminates the dangers of accidental short circuits.
BULB
HYDROGEN
GAS
-5-
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. A
copy of IS:266 1993 is enclosed at the end of the manual.
To dilute strong acid, the quantities required for mixing are given below:
1.840 1.190 87 18
1.825 1.400 66 40
1.825 1.190 86 18
1.400 1.190 56 45
Note : When acid and water are mixed, there is a volume contraction, hence
columns 3 & 4 do not total 100.
(iv) Caution:
-6-
6. Smoking, Welding Arcs, Electrical Sparks and Open Flame should be strictly
prohibited 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 their
accidental falling / touching of live parts and causing short circuit.
9. Temperature Correction
The specific gravity of the electrolyte varies with temperature. Any reading
observed on the hydrometer should therefore be corrected to 270 C ,as all
the 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 the
hydrometer. Similarly, for every 10 C below 270 C subtract 0.0007 from the
specific gravity as read from the hydrometer.
10. Installation
The following should be kept in mind while finalising the battery layout:
Suitable insulators should also be used between the stand or Stillage and
the floor. Arrange cells to that the positive terminal lug of one cell adjoins the
negative terminal lug of the next throughout the battery. Use a wooden
spacer to ensure even spacing out of cells.
-7-
(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 of
each terminal pillar with petroleum jelly and tighten the bolt connectors firmly
using two spanners, one on the bolt head and one on the nut.
Clean off any flux and bind the exposed end of the cable with self adhesive
tape starting well back on the cable insulation and ending just at the lead
cable socket. All copper work should be painted with two coats of acid
resisting enamel paint before the cells are filled with acid.
(iv) Connect cells together :
When the cells are in position on the stands, connect them together Smear a
little petroleum jelly on the threads, bolting faces and in the bolt holes before
bolting up. If necessary, warm the petroleum jelly to ensure a thin even
coating. After bolting-up the cells smear petroleum jelly over the nut, bolt
head and washers.
-8-
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 per
cell by the number of cells adding 10% to compensate for spillage.
The acid should be brought to equilibrium with the room temperature and of
1.190 Sp. Gravity. This acid should be carefully poured into the cells, up to
the maximum recommended level.
After filling in allow the cells to stand for a period of 8-12 hours. The plates
will absorb the electrolyte and the electrolyte level will drop. Restore the
electrolyte level at the end of this 8-12 hours period by adding more acid of
1.190 Sp. Gr.
c) Recording the total battery voltage and comparison thereof with the
sum total of individual cell voltage.
Check and check again to ensure the cells are all connected in series and all
fastenings and connections are tight.
Test polarity of the charging leads and connects the positive terminal of the
battery to the positive lead of the charger.
Caution : Charging a cell or battery in the wrong direction will ruin it.
-9-
(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. Reduce
charging current if temperature of electrolyte exceeds 500 C. Charging at this
rate 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 12
hour and not less than 2 hours should be given.
The second portion of the charge must be given at the finishing rate as
mentioned in the relevant technical particulars. This stage to continue till
either the signs of completion of charge are observed or the minimum Ah
input required (as mentioned in the relevant technical particulars) is
administered, whichever happens later.
This is very important for the life of the battery that the first charge be
administered very particularly so far as the Ah input is concerned.
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 the
state of charge of the whole battery.
a. Specific Gravity
b. Voltage
c. Temperature
When all these signs of completion of charge have been observed, and the
minimum Ah input required (as mentioned in clause 12(v)) is administered, the
charge should be terminated. About one hour afterwards, when the gas bubbles
have cleared away, the specific gravity and temperature should be recorded.
During charging the electrolyte temperature of the cell should not exceed 500C.
Suspend the charge if the temperature reaches 500 C and resume charging after
the battery has cooled to about 450C. If necessary, slightly lower the recommended
charging rate in case of very high ambient temperatures. Where ambient
temperatures are normally high, it is recommended that charging be carried out
during the night and suspended during the day. If necessary, use the finishing rate
for the first portion of the charge as well. When charging is suspended due to
attainment of high temperatures, such stoppages should be noted carefully and the
duration shall be suitably extended to compensate for such stoppages.
(vii) Interruptions
Maintain the level throughout charging adding 1.190 Sp. Gr. Acid if
necessary.
- 11 -
(ix) Adjust Specific Gravity of Each Cell
If at the end of the first charge the specific gravity of the electrolyte exceeds
1.205, withdraw some electrolyte and add pure water, continue the charge
so that the water and acid mix thoroughly.
If at the end of first charge the specific gravity of the electrolyte is below
1.195 after both voltage and specific gravity have remained constant over 3
consecutive hours, withdraw some electrolyte and add acid of 1.400 specific
gravity continuing the charge in the meantime.
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 gravity
acid or by withdrawing excess electrolyte, as required.
After correcting specific gravity and electrolyte levels, start a record book for
the whole life of the battery. The first page should record the specific gravity
readings 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 and
discharges etc.
A record book is supplied with each battery of 60 volts and above; for
smaller batteries this can be obtained at nominal charge. If one copy of this
record sheet is sent periodically to the nearest office of the Company, free
technical advice will be given so that the battery is maintained in optimum
conditions.
The first charge sheet supplied with the battery should be filled up with the
readings obtained during initial charge and returned to the Company for
comments.
(xi) Cleaning up
Wipe down the outside of all cells and clean up any acid which may have
dripped or have been split on the cell lids, stand on floor. Check generally
that everything, is in order.
(xii) Storage
- 12 -
13. Operation
(i) It is important that the battery should be operated in accordance with the
instructions given by the manufacturer.
Make sure that the instruction Display Board is hung in a prominent and
accessible location in the battery room.
Adjust Float / Trickle charge current to the required value as per instructions
given by the manufacturer.
The proper operation and correct adjustment of the charging supply ensures
trouble-free operation and life of the battery. It determines the rate and amount of
charge received and thus indirectly its temperature and water requirements.
- 13 -
The re-charging of the batteries is accomplished with the float charger supplying
current to the battery. The load current as well as any other current supplied by the
battery must be restored to the battery in service.
If sufficient current is not available from the charger, the battery will run down and
eventually fail to cater the back-up time. On the other hand, if more current than
necessary is furnished, the battery life will be shortened. It is therefore highly
important than the charging is proper for the life & performance of the battery bank.
The battery is float charged from a D.C source. The output of which is controlled to
keep the voltage at the battery terminals at nominal value 2.26 vpc. Under these
conditions of constant voltage charging, the battery regulates its own charging
current.
Under normal conditions, the battery should be in a high state of charge ready for
an emergency discharge and a low steady Trickle Current.
The value of the charging current, therefore, gives a rough indication of the state of
charge, if charging voltage is maintained 2.26 vpc.
Charging voltage:
- 14 -
LOW VOLTAGE SETTING:
EQUALISING CHARGE:
During the operation of the battery, under constant potential charge, there is a
chance of imbalance amongst the cells in the bank. This may occur due to various
reasons, e.g. initial differences between individual cells, differences in charge
acceptance, or abnormal working conditions. As a result some cells shall remain
continually undercharged.
If the Lead Acid cell remains under-charged over long periods, the resulting
sulphation 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 the
cells in the battery bank to a healthy state.
BATTERY MAINTENANCE:
Routine maintenance must take account of the following factors and maintain
proper record, which are inter-related and are of equal importance:
- 15 -
each occasion. Once this experience has been gained, the interval between
inspections 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 that
partly discharged battery would not be very reliable source of power in case of
emergency.
The Inspection Register should be kept in a holder located on each Battery Room
so that the desired information can be recorded. Each Cell should be marked with
an identifying number.
Batteries shall receive regular monthly and annual inspection in addition to any
other attention that the user may desire to give or which may be necessary.
MAINTENANCE SCHEDULE
The maintenance schedule given here is divided in daily, weekly, monthly and
yearly maintenance. The actions to be taken, checks and recording required are
given herewith.
A. DAILY MAINTENANCE
B. WEEKLY MAINTENANCE
1. Check electrolyte level of all cells and if required, top-up with battery
grade water conforming to IS 1069. Never use metal vessels for
topping up because of the risk of electrolyte contamination and
accidental short circuit. Excess water loss may occur due to internal
short, high voltage setting etc. Corrective measures to be taken
immediately.
- 16 -
2. Visually check the conditions of each cell and battery bank. If
abnormal or very high amount of sulphation on the terminals or
connectors are observed, take immediate action in removing them.
Deposits to be cleaned with wet cloth followed by dry clean.
C. MONTHLY MAINTENANCE
A monthly maintenance shall include all checks listed under daily and
weekly maintenance schedule and also the following :
1. Check and record specific gravity, voltage and temperature of all cells
in the battery bank.
D. QUARTERLY MAINTENANCE
1. Check and record specific gravity, voltage and temperature of all cells
in the battery bank.
- 17 -
E. HALF YEARLY MAINTENANCE
A half yearly maintenance shall include all checks listed under daily,
weekly, monthly and quarterly maintenance schedule and also the
following :
F. YEARLY MAINTENANCE
A yearly maintenance should include all items listed under daily, weekly
and monthly maintenance schedule and also the following :
5. The battery bank can be given back to the system after the equalising
charge is over.
- 18 -
EMERGENCY INSPECTION
If battery failure or other difficulty is reported, include the following checks and tests
in sequence:
a) Measure total voltage of battery on open circuit and under load. If this is
normal, 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 battery
has discharged with suitable load. Recharge the battery. Locate the cause
and rectify.
d) Read voltage of individual cells at the same time looking for any hot cells or
any other abnormal conditions.
If one or more cells are found reading low voltage, read their voltage under
load and if it is quite low in comparison with other cells, which is probably the
immediate cause of trouble. Rectify the low voltage cells / Replace with
spare Cells to get the battery in service quickly.
OVERHAULING
Depending on visual inspection at site Plante battery bank may need partial or
complete overhauling after 8-10 years.
MISCELLANEOUS 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.
d) Take particular care, avoid short circuit by bridging the terminals with
spanner while tightening terminal nuts & bolts.
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.
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
charged conditions.
It is therefore; very important that there should be an optimum consumption
of water since this indicates that a full state of charge is being maintained.
Lower water consumption indicates abnormal conditions; e.g., either a low
charging voltage or excessive non-emergency discharges in consequence of
which the battery is not being kept in a charged condition. Steps should be
taken immediately to eliminate the cause of low water consumption.
Water consumption markedly higher than usual suggests that the existence
of a high charging voltage and this should be checked immediately and
adjusted if necessary.
Some important instruments and tools that are necessary for proper
maintenance of battery are listed below: -
- 20 -
(iv) 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 and debris
should be selected for storage space. Keep them with vent plugs on.
b) Testing: Spare charged batteries should be checked at regular
monthly intervals to determine the specific gravity. Batteries should be
charged before the specific gravity drops 30 points below the
specified fully charged readings. Temperature affects the need for
charges.
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 majority of the
lowest cells has risen to the maximum and has shown no further rise
for three consecutive hourly readings.
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ADVICE AND INSPECTION :
- 22 -