MAINTENANCE SCHEDULE FOR STATIONARY BATTERY SET AND

BATTERY CHARGER

Item Frequency of Item to be Inspected Inspection

No. Inspection
1 2 3 4
1. Daily Float charger Auto Float charger output voltage should be between Defect
Mode the values given below: charge
110 V Battery Set 220V Battery Set float c
118 V to 121 V 236 V to 242 V mainta
2. Daily Battery set connected Switch off the battery charger. a)(i) If
to load. a) Observe D.C. voltage:
In case D.C. voltage disappears as soon as the
float charger is switched off, or, instead of full (ii) I
D.C. voltage, the battery tap voltage is
observed, and then the float charger is to be -
switched ON immediately.

b) Check that the battery is discharging to the b) If th

load by observing the charge / discharge mea
ammeter which should show current on batt
discharge side. Return charger to normal disc
operation.

1 2 3 4
3. Daily (i) Conventional (i) Check the specific gravity of the cells and (i) If s
Battery Set. temperature of cell no.55 / 110 & convert the at
Specific gravity of specific gravity to 27°C as given at ac
cell nos. 1, 28, 55, Instruction no. 8.
82, 110 as
relevant.

(ii) Maintenance free (ii) Check the voltage of the cells and the (ii) If
VRLA type temperature of the Battery Room & convert av
Battery Set. the voltage to 27°C as given at Instruction no. ch
Voltage of cell 19. ch
nos. 1, 28, 54, 82, re
110 as relevant.
4. Weekly (i) Conventional a) After switching off the charger {Follow a(i) I
Battery Set. precautions at item No. 2 (a) above}, check
Specific gravity, specific gravity and voltage of all the cells and
electrolyte level the temperature of cell No. 55 / 110. Return
and voltage of all charger to normal operation. Convert specific a(ii) I
the cells. gravity readings to 27°C by the formula :
{SG 27°C=SG t + 0.7 (t - 27°C)}.
The values of specific gravity at 27°C &
voltage should be as below :
Specific Voltage
Sl. Gravity per cell Sl.No.
No. MAKE at 27°C (min.) i)
i) STANDARD 1210+5 2.0 V ii)
ii) AMCO 1200+5 2.0 V iii)
iii) EXIDE 1200+5 2.0 V a(iii)

1 2 3 4
 a(iv)If
ab
th
th
tre

b) Check the electrolyte level. b(i) If

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di
NEVE
W
ba
cu
di
th
b(ii)In
ele
wa
ba
co
(S

(ii) Maintenance free (a) After switching off the float charger {follow a) If
VRLA type precaution at item No. 2 (a) above}, check flo
battery set. the voltage of all cells and ambient ch
Voltages of all temperatures. Convert voltage readings to pe
cells 27°C by the sta
formula:
V 27°C = Vt - 0.003 (t -27°C).

The minimum value of voltage at 27°C should be

2.15 volts per cell.

1 2 3 4 5
5. Weekly Battery Check for cleanliness & a) Clean all the cell
Cells. dust / moisture deposits containers, stand and
& leakage. insulators and attend
leakage, if any. Apply
Vaseline / petroleum
jelly on terminals,
intercell connectors
and nuts and bolts
wherever necessary.
Alternatively, use CRC

b)
6 Monthly Battery Set Switch off the float a)
Capacity charger for one hour
Status. {Follow precautions at
item no. 2 (a) above} &
observe drop in battery
voltage.
The battery Voltage
should not drop below
107 V for 110 V battery
set & below 214 V for
220 V battery set. b)
If the voltage does not
fall below the values
given above, switch on
the float charger & then
. give boost charge to the
battery set as below.
(i) Conventional c)
battery set.
At a current given
at item No.4 a (ii)
for 2 hours.
(ii) Maintenance free
VRLA battery set.
Charge at 2.30 Volt
per cell for 2 hours
or till charging
current becomes
negligible,
whichever is earlier.
(Bharat Bijlee or any
standard make) instead
of Vaseline / petroleum
jelly.
In case of conventional
type battery set ensure
that the rubber seal at
the base of the
terminals & on cell lid
is fitted properly.
Replace if damaged.
Rapid fall in voltage
could be due to loose
connections or
corroded terminals.
Switch on battery
charger. Clean
corroded parts with
warm water as per
procedure at Item No. 7
and tighten loose
connections.
Switch off the float
charger again for one
hour. If the battery
voltage still drops
below the limits given,
recharge the battery set
as per instructions
given at Item No. 11
given below.
Switch off the float
charger again for one
hour. If the battery
voltage still drops
below the limits given,
this could be due to
weak cells. Check the
voltage of all the cells
keeping the float
charger off. Return
charger to normal
operation.
For conventional
battery set
If the voltage of
 majority of the cells is
below 2.0 V, then the
battery set should be
considered to have
lost its capacity and
battery set should be
replaced.
However, if the voltage
of only some of the
cells is below 2.0 V,
then such cells are to
be considered as weak
cells and treated in
accordance with
Instruction No. 9. The
treated / replacement
cells should be refitted
in the battery set.

1 2 3 4
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tak
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to
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un
sta
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d) Sw
th
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ba
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12
be
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sh
7. Monthly Corroded terminals a)Check for sulphate deposits on terminals of a) For
 cells, inter-cell connectors and nuts & bolts. the
Inter-cell connector using robust & reliable conn
connection. atten
has
clea
coat
Inst
conn

2 3 1 4
b) Check for corroded / damaged terminals, inter- b) Rep
cell bolt
connectors, and nuts & bolts. abov
c) Tigh
c) Check nuts & bolts for tightness.
d) Was
d) Check vent plugs. wate
8. Monthly Battery Charger a) Check for cleanliness. a) Clea

b) Check for loose connections. b) Tigh

c) Check operation of float charger by putting it c) If t

in manual mode and slightly raising the float curr
output voltage. The charge / discharge not
ammeter should show current on the charge corr
side. Return charger to auto mode. boo
Key
For
and
char
volt
give
butt
is to

d) Check the operation of the boost charger by d) If th

switching on the boost input & output switches curr
/ MCB ( with coarse & fine switches in not
minimum position) & slowly increasing the rect
boost output voltage by operating the coarse &
fine switches till the charge / discharge
ammeter shows current on the charge side.
Switch off the boost charger and return the
coarse and fine switches to minimum position.
 1 2 3 4
9. Quarterly. Open circuit voltage Disconnect the battery set from the float charger The D
(Applicable for of battery cells. by switching ON boost A.C. supply in the gives
VRLA battery charger. As the load is connected to float charger,
indicat
set only) the battery set is in open circuit condition. Boost (i) If
output D.C. switch should be kept OFF and sw
coarse and fine selector switches should be at th
minimum position during this time. Check the dr
voltage of the cells after 3 Hours. (ii) If
ba
tap
10. Half Yearly or Battery Set Check the voltage of all the cells with the float (i) If th
as Required. charger ON. ce
(Applicable for ba
VRLA battery un
set only) sta
ea
ho
(ii) If t
0.
Fo
sta
di
by
th
ce
th
th
co
ho
co

1 2 3 4
11. Yearly Curative Discharge After switching off the float charger, discharge By th
(Conditional) ( to be conducted if the battery at its 10 hour rate discharge current probab
conditions permit (12 Amps for 120 AH, 20 Amps for 200 AH, & chargin
shutdown of the sub- 40 Amps for 400 AH capacity battery set
station & after respectively) for a period of 2 hours.
arranging back feed
supply for recharging Recharge the battery set as given below.
the battery set ).
(i) Conventional battery set Values
At the recharge current till the cells start gassing Gravit
freely. Then reduce current to the finishing rate &
charge until the specified value of specific gravity Sl. M
is attained and remains constant for three No. C
consecutive hourly readings. Also refer i) St
Instruction No. 12. ii) St
iii) St
iv) A
v) AM
vi) A
vii) EX
viii) EX

(ii) Maintenance Free VRLA Battery Set

At a constant voltage of 2.30 V / cell till the
current reduces and stabilizes to a minimum value
and three consecutive hourly readings of voltage
of all the cells remain constant.

1 2 3 4
12. If monthly Capacity check (to be The discharge should not be done when The te
inspection of done under shutdown electrolyte temperature exceeds 35°C unless it is conven
capacity status only, & after unavoidable. Battery
as per item No. arranging back feed hourly
6 above shows supply for recharging After switching off the float charger, discharge
unsatisfactory battery set). the battery set at its 10 hour rate discharge current The av
condition. as given in item no. 11 above till the following that of
values are reached : dischar
i) 220 V battery set : conven
(a) For conventional type battery set: respect
Close circuit voltage across battery set falls
to 203.5 V or voltage across any one cell The pe
falls to 1.70 V whichever is earlier. curren
(b) For VRLA type battery set: tempe
Close circuit voltage across battery set falls capac
to 192.5V, or voltage across any one cell formu
falls to 1.75V whichever is earlier. Capac

ii) 110 V battery set :

(a) For conventional type battery set: SHUT
Close circuit voltage across battery set falls RETU
to 101.75 V or voltage across any one cell HAS B
falls to 1.70 V whichever is earlier. (A) F
(b) For VRLA type battery set: CE
Close circuit voltage across battery set falls (B)FO
to 96.25 V, or voltage across any one cell BA
falls to 1.75V whichever is earlier. VO
Time in hours elapsing between beginning and
end of discharge shall be taken as the period of CHAR
discharge. BATT
Recharge the battery set as given in Item no. 11 ITEM
above.
13. Yearly Battery Stand Clean the stand and insulators under the battery Repla
cells. with e