MANUAL

GSYUASA Q-1 1 G-I

Oct. 2005

INSTRUCTION MANUAL
FOR
GS Yuasa VENTED TYPE
STATIONARY ALKALINE STORAGE BATTERY

GS Yuasa International Ltd.

 CAUTION1

Failure in Giving Cautions will Result in Following. Reference for

Item Details
Conditions Results

Setting voltage too .Life will be shortened.

accelerated and
high. Electrolyte reduction is
water replenishment intervals are shortened.
Floating Charge 4.3.(1)
Voltage Capacity will be decreased.
Setting voltage too Inactivation will proceed and performance
low.
characteristics will decrease.

Replenishment being Will develop oxidation, heating and burning

forgotten. if plates are exposed.

Excessive replenish- 4.3.(4)

Water Replenishment ment.
Will develop overtlow causing leakage.

Will shorten life.

Use of impure water.
Will decrease performance characteristics.
Characteristics of cell groups will be unbal-
Periodical Equalizing Not performed. anced. 4.3.(2)
Charge Will shorten life.
O
.Will shorten life.
Battery Temperature Use at above 45°C
Thermal runaway may occur.
7.(9)

Not performed. Will cause leakage and faster corrosion.

Use of dry cloth or .Will generate static electricity which may

Cleaning "dusters". cause ignition and explosion of battery.
4.3.(5)

Cleaning by organic .Will damage parts made of plastics.

solvent. (Container, cover, etc.).

Prohibition of Fire .Will ignite and explode battery.

Prevention of External May damage not only parts due to sparks, but also battery due to
Short Circuit explosion.

Battery may be damaged by burning when electrolyte is depleted.

Electrolyte Depletion

Prohibition of Sulfuric .May corrode or dissolve parts to shorten batterylife if sulfuric acid is
used by mistake.
Acid

Handling of Electrolytelf deposited

on eye, it may cause loss of eyesight.
Cautions on Electric I f touched on electrically conductive parts, one may get electric shock.
Shock

Note: The storage battery is shipped in discharged and empty. Therefore, the battery, when put into
service, requires filing of electrolyte and initial charge (300% of rated capacity).
For the method, refer to the separate "Installation Manual of Stationary Nickel Cadmium Alkaline
Storage Battery (Vented Type)"
 CAUTIONN2

While the storage battery is shipped in discharged condition without electrolyte, in order to
prevent drying up of the separators and plates the battery cell is given sealing treatment
such that the frilter plug is filled with rubber sealing plug in its interior and the filter plug
cover is covered with a sealing tape fastened to the container.
Caution Label

Sealing Plug
Filler Plug

Sealing Tape

The sealing tape is affixed with the following caution label.

DATE OF EXPIRY:
AT FILLING REMOVE AND DISCARD THE RUBBER PLUG IN THE FILLER PLUG

Also, the outer wood box and inner cardboard box of the package are affixed with the fol-
lowing caution label

THIS STORAGE BATTERY MUST BE FILLED WITH ELECTROLYTE WITHIN

THREE YEARS AFTER MANUFACTURE.
DATE OF MANUFACTURE:
DATE OF EXPIRY:

Both labels indicate that the storage battery must be filled with electrolyte within two years
after manufacture. If the interior of the battery dries up, it may cause the characteristics to
deteriorate making the battery incapable of operation. Be sure to fill electrolyte within the
above period.
 CONTENTS
Page
1. General..
2. Component Parts of Alkaline Storage Battery
2.1 Pocket Type Plates 2
2.2 Sintered Type Plates
2.3 Separators... 2
2.4 Containers and Covers. 2
2.5 Other Parts...
2.6 Electrolyte.... 2
2.7 Construction. .. 3

3. Characteristics of Alkaline Storage Battery..

3.1 Chemical Reaction at Charge and Discharge.
3.2 Discharge Characteristics
3.3 Charge Characteristics
4.
Maintenance of Alkaline Storage Battery...
4.1 Maintenance...
10
10
4.2 Inspection and Treatment.
(1) Monthly Inspection.. 11
(2) Six Month Inspection.... 11
(3) Yearly Inspection. 12
4.3 Methods of Maintenance 12
(1) Floating Charge. 12
(2) Equalizing Charge. 12
(3) Recovery Charge... 13
(4) Water Replenishment.. 13
(5) Cleaning 14
(6) Additional Tightening of Connections 14

5. Special Maintenance... 15
Specific Gravity Check. 15
5.2 Activation.. 15
5.3 Electrolyte Replacement 15

How To Use Maintenance Tools.

6 16

7. Cautions.. 19
8. Troubleshooting .. 20
9. Long Term Storage of Battery.. 22
10. Disposition of Used-out Battery and Electrolyte. 22

Appendix 1 4: Alkaline Storage Battery Specification. 23

5: Data Sheet of Capacity Test. 27
6: Handling of Optional Parts.. 28
7: Flow Chart of Main Troubleshooting.. 29
 This manual describes as construction, characteristics and maintenance of vented type alkaline
storage battery. In general, the performance and life of a sto battery are largely affected depend-
ing on whether it has been handled and maintained adequately or inadequately. Before putting the bat
tery into service, read this instruction manual thoroughly and give adequate maintenance according to
what is called for in the manual to keep the battery in good condition at all time.

1. General
This storage battery is Nickel Cadmium Alkaline Storage Battery using nickel hydroxide as
the positive active materials, cadmium as the negative active material and caustic potash solution
as the electrolyte.
The battery is used on floating charge system being connected with charger and load as
shown in Fig. 1.

AC
DC
Load
Charger

- Load Compensation Equipment

Alkaline Storage Battery (Installed as required)

Fig. 1: Block Diagram of Floating Charge System

This floating charge system is used in the following manner. Normally the system is used on
mode. That is, the charger will supply the power to load while supplying the current of
floating charge
small amount to the battery to compensate self-discharge.
the battery starts without
When the rectifier stops the operation due to AC power supply failure,
duration.
interruption to supply the power to load for the required
restoration of AC power supply, the battery shall be
After the rectifier restarts the operation upon
device may be provided.)
given a recovery charge by manual operation. (Automatic recovery charging

- 1
2. Component of Alkaline Storage Batteries
Alkaline storage batteries are classified in two kinds,
the pocket plate type and the sinta red
plate type. Their constructions and component parts are as follows.

2.1 Pocket Type Plates

Positive and negative plates are made of polished band steel of which portions to
plate surface are perforated with innumerable number of microporous, and formed ubonome
plating into pocket forms by continuous enveloping process, which are filled with activa Ke
with nickel as main
hydroxide for positive plates and active material
constituent
main constituent for negative plates. A desired number of these formed pockets is as
with caderal
a current collector to comprise a plate.
connected
ected to

2.2 Sintered Type Plates

Positive and negative plates are made of thin polished band steel upon which small noran
are perforatedand on which surface, nickel powders
are sintered at a high
microporous sintered base plates, inside of which are impregnated with nickel temperature to form
material for positive plates, and with cadmium hydroxide as active material hydroxide as activee
for negative plates
2.3 Separators
Being inserted between positive plates and negative plates to prevent short circuits
the plates, the material used is of excellent between
anti-alkalinity such as high quality synthetic resin.
2.4 Containers and Covers
Containers are made of synthetic resin with high mechanical
enabling to see the strength and with transparency
electrolyte level through the walls, and are provided with electrolyte level indi-
cating lines on their sides.
Covers are made of synthetic resin with
enter with filling opening for
high mechanical strength and are provided on the
emitting gases outside the cell or for replenishing water. The filling
opening is fitted with a filler plug.
The container and cover are
the plate element in the container. permanently
sealed by adhesive agents after accommodating

2.5Other Parts
Such metallic parts as poles, bolts, nuts and connectors are protected by nickel plating of
high anti-alkalinity. Other parts such as gaskets, etc. are all made of anti-alkaline materials.

2.6 Electrolyte
Electrolyte is an aqueous solution of high purity caustic potash with specific gravity of 1,200
(20) as standard.
Electrolytes are different in specification between the pocket plate type at
ETY and the sintered plate type battery. The specification is shown in Table 1. Be careful not To
make mistakes in
procurement and use.

Table 1: Specification for Electrolyte of Alkaline Storage Batteries

Item Type Pocket Plate Type Sintered Plate Type

Appearance No Color, Transparent, No Suspended Matters
Specific Gravity (20°C) 1.20
Composition Caustic Potash
270 g/0
Lithium Hydroxide 4.5 g/e 4.5 g/
Impurities Chlorine Less than 0.15 g / e
Potassium Carbonate Less than 3 g/e

-2
2.7 Construction
An example of the construction of alkaline storage batteries is shown in Fig. 2.

Pocket Plate Type Sintered Plate Type

(0-

5
6-

Fig. 2: Construction of Alkaline Storage Battery

Major Components

No. Parts Name

Filler Plu9
Pole Strap
Cover
Gasket

Negative Plate
Separator
Positive Plate

Container
Spacer

-3
3. Characteristics of Alkaline Storage Battery
3.1 Chemical Reactions at Charge and Discharge
When an alkaline storage battery is in charged condition, the positive active material
a
active material is a metallic cadmi
high grade hydroxide of nickel (NiOOH) and the negative mium
(Cd).
When an external circuit is connected to the storage battery, an electrochemical react.
at which the positive active material is reduced to a low grade ction
nio
takes place inside the battery
active material is oxidized to a cadmi
el hydroxide {Ni(OH)2}, and simultaneously the negative
to flow externally from posITive pole to negative Dole
hydroxide {Cd(OH)2} making electric current pole.
This is the discharge phenomenon.
When DC current is applied to the discharged battery from an external source (that is, whan
the battery is charged), an electrochemical reaction takes place inside the battery in a direction
opposite to that at discharge, making the battery to revert back to the state prior to discharge.

formulas.
These reactions can generally be described by the following

Discharge 2Ni (OH)2+20H

Positive: 2NiOOH+2H20+2e
Charge

Discharge C d (OH)2 + 2e
Cd+20HH
Negative:
Charge

Discharge 2Ni (OH)2+ Cd (OH)2

Entire Battery: 2NiOOH+ Cd+2H0 Charge
As one can understand from the above reaction formulas, caustic potash (KOH)in the elec-
trolyte does not participate in the reaction directly, and water (H20) is consumed at discharge but
is produced again at charge, therefore specific gravity change in the electrolyte is almost negligi
ble.

3.2 Discharge Characteristics

(1) Discharge (Rating)
Ratings on discharge capacities of each type of alkaline storage batteries are as shown in
Table 2.
Discharge chat cteristics with discharge current variations and discharge characteristics
with temperature variations are shown in Fig. 5 to Fig. 12. The larger the discharge current, the
lower the performance and the less the discharge capacity. Also the lower the using tempera
ture, the lower the performance and the less the discharge capacity.
Table 2: Ratings of Alkaline Storage Battery
Battery Model Rating
JIS Discharge Final Discharge Electrolyte
Type Model Discharge
Model Hour Rate Current (A) Voltage Temperature

Pocket Plate QKC AM-P 1.00V per cell

Type QsC AMH-P 5 HR 0.2 C 1.00V per cell 25°C
Sintered Plate QFD AH-S 1.00V per cell
Type QFG AHH-S 1 HR 1 1.00V per cell
Note 1: These ratings are based on JIS
C8706.
2: "Cin
discharge current column denotes the value of rated capacity of storage battery.

-4-
 ujul- SJu) (uju)
eul DEyosia p0]0e0o au a6ieyosia paj800
3
L
 After Capacity Test
(vi) Recovery Chargehas been discharged, perform immediately a
charge
recovery charge in accor
After the battery restore the capacity.
dance with Item 4.3.(3) to
below 35C.
at temperatures
Note: Perform the charge
(vii) Data Taking
from among 20 cells (minimum
of more than two o
Select arbitrarily one pilot cell
the result in the data sheet specified below, cells).
Perform measurement and record
(a) Discharge Data
Pilot Cells..
' ' Table 3
Table 3 (A)
ACCells..
(b) Charge Data
Table 3
Pilot Cells. *
...
' ' ' ' "

Table 3 (B)
All Cells
Table 3: Data Sheet

Installation Location:
Data Taken On: (Date)
Model:
Discharge Current: Measured by:
Mfg. Date:
D No.
Discharge Time Electrolyte Disch.
Total Unit Room
Volt. Cell Measured Corrected Temp. Curr. Temp.
AM-P, AMHP AHH-S Volt. (A) (°C)
AH-P, AH-S (V) Sp. Gr. Sp.Gr.(20°C (c)
Just before discharge O O O
Just after discharge O O O O
30 min. 5 m. O O
1 hr. 10 m. O
2 hr. 20 m. O
4 hr. 30 m. O O O O
6 hr. 40 m. O O
O O
8 hr. 50 m. O O O
9hr. 55 m O O
10 hr.
60m. O O O O
Note: Columns marked with O
require measurement.
(A) For Discharge
(B) For Charge
Cell Before Discharge End of Discharge
No. Cell Before Charge End of Charge
Volt. Temp. Volt. No.
Temp. Volt. Volt. Temp.
O Temp.
O O O O O
O O O O
3 O
2
O O O
3 O O O
O O O
O O O
O O
O
O O O
Note: Columns marked with
O O O
mark require measurement
3.3Charge Characteristics
Methods of charging the discharged
Current charge
constant voltad
and batteries are classified
rge. in two kinds,
charge characteristics are showr
Constant current namely constant
the charge current, but
on wni
depending as Figs. 13 to 16. Charging time varies
for sintered type andcharge amount (Ah)
140% for requirement the charge is
pocket type
Constant voltage charge of the
discharged continueo
amount
the equalizing charge described in are characteristics
shown in Figs. 17 and
18. Charging
(AH
SIraaraph 4.3(3). Cnarge current remainsParagraph 4.3(2) and the recovery charge method is
oltage, but after almost
reacing tnat value the current constant described
until charge voltage reaches the
decreases sharply to a very small value.

1,40
1.40
1.30

1.20
1.10
0.5 C 1.00
5
0.90
O.80
0.80
80
100 Capacity (%) 0
Capacity (6)
0.1 C (hr)
3 5 Discharge Time (hr.)
0.2C (hr.) Capacity and Discharge Time

0.5 C (min.)
L
50 1C (min.)
Capacity and Discharge Time

Fig.5: Pocket Plate Type Alkaline Storage Fig. 6: Pocket Plate Type Alkaline Storage
Battery Battery
QKC Type (AM-P Type) Discharge QKC Type (AM-P Type) Discharge
Characteristics at Various Rates Characteristics at Various Discharge
Temperature: 25°C Current: 0.2C

40
40
1 30
1.20 ESE
20
1.10 5C
10 .2 C 1.00
1.00 5 C
0.90
0.80
0.80 100 Capacity ()

100 Capacity (o L 4 5 Discharge Time (hr.)

40 ) Capacity and Discharge Time

L 0.2 C (

120
0.5 C(min.)
100
20 1 C (min.)
50
2C (min.)
20
Capacity and Discharge Time
Pocket Plate Type Alkaline Storage
Storage Fig. 8:
ig 7: Pocket Plate Type Alkaline Battery
Discharge
QSC Type (AMH-P Type)
Battery Characteristics at
Various Discharge
Type) Discharge
OSC Type (AMH-PVarious Current: 0.2C
Rates
Characteristics at
Temperature: 25°C
 1.40

1.40
1.30
20
1.30

0.2 C 10
5C
1.10 1.00
1.00 0.90
0.90 0.80
3C
0.80 0 0 0

20
B0
100 capacitly (%) L Capacity (%)
5
0.2C (hr.)
Capacity and Discharge Time Discharge Time (hr)
20
1C(min.)
0 2C (min.)
3C (min.)
Capacity and Discharge Time

Fig.9: Sintered Plate Type Alkaline Storage Fig. 10: Sintered Plate Type Alkaline Storage

Battery Battery
QFD Type (AH-S Type) Discharge QFD Type (AH-S Type) Discharge
Characteristics at Various Rates Characteristics at Various Discharge
Temperature: 25°C Current: 0.2C

1.0
02
00
c |25°C
O.90 0.90
0.80
0.80
0 00 apacity (% Capacity (')
0.2 C hr.) 24 Discharge Time (hr)
1 C (min.) Capacity and Discharge Time

3C (min.)

10 5C (min.)
Capacity and Discharge Time

Fig. 11: Sintered Plate Type Alkaline Storage Fig. 12: Sintered Plate
Battery Type Alkaline Storage
QFG Type (AHH-S Type) Discharge Battery
QFG Type (AHH-S Type) Discharge
Characteristics at Various Rates
Temperature: 25°C Characteristics at Various Discharge
Current: 1C

80

1.70 1.80
O.1 C
60 1.70
02C 0.1
60

40

30
Temperature:
5+5C
20 30 Temperature.
t 5 °C
10

4
Charge Time (hr.)
Fig. 13: Pocket Plate
Type Alkaline Storage Charge Time (hr.)

Battery Fig. 14: Pocket Plate Type Alkaline Storage

QKC Type (AM-P
Type) Charge Battery
Characteristics QsC Type (AMH-P Type) Charge
Characteristics
 1.80
.80
1.70
0.2C 1.70
1.60
02G
1.60
1.50

1.40
1.40
1.30 Tenpernro entperaUrG.
130
20

10
1.10

8 10 12 4 14
0
Charge Time (hr.) Charge Tme (hr.)

Fig. 15: Sintered Plate Type Alkaline Storage Fig. 16: Sintered Plate Type Alkaline Storage
Battery Battery
QFD Type (AH-S Type) Charge QFG Type (AHH-S Type) Charge
Characteristics Characteristics

1.70

1.60 Charge Voltage

50

-=------------
140 40

Charge Amount
120 1.30
Charge Current
100 0.1

80 008
60 0.06

0.04

200.02
0- 0 10 12 14 1 16 1 8 2 0
Charge Time (hr.)

Fig. 17: Pocket Plate Type Alkaline Storage Battery (QSC Type AMH-P Type) Charge
Characteristics (Floating charge system, recovery charge)
State Before Charge: Fully Discharged
Charge Setting Voltage: 1.58 V/cell
Charge Drooping Current: 0.1C

1.60

1.50 Charge Voltage

1.40

140 1.30
Chargel Amount
120
Charge Curtent
100 0.1

80-0.08
60 0.06
408 0.04
200.02
10 2 14 18 20
0
Charge Time (hr.)

Battery (OFG Type AHH-S Type) Charge

Fig. 18: Sintered Type Alkaline Storage
Plate
recovery charge)
Characteristics (Floating charge
system,
Fully Discharged
State Before Charge:
1.47 V/cell
Charge Setting Voltage:
Current: 0.1C
Charger Dropping

-9
4. Maintenance of Alkaline Storage Battery
4.1 Maintenance
Maintenance shall be performed based on the following list. (O mark indicates mainten
nance
to be carried out.)

Inspection Periodical Inspection Perform Performed

Interval| One Month MonthsOne Year
as
in Special
Item To Be (Spontaneous SIX required
Performed inspection) 4.2.(2) 4.2.(3) Cases
4.2.(1)
Verification of Total Voltage in O
O
Floating Charge
Adjustment of Floating Charge O
Voltage
Calibration of Reading of
Voltmeter on Panel
O

Verification of Voltage of All Cells

O O
During Floating Charge

Confirmation of Electrolyte Level O O O

Equalizing Charge O

Recovery Charge Refer to

(4.3.(3))
Water Replenishment O
Refer to
(4.3.(4))
Confirmation of Battery
Temperature (pilot cells) O O
8 Confirmation of Existence
of Leakage O O O
Confirmation of other
General Conditions O O

Cleaning
Refer to
Additional Tightening of (4.3.(5))
Connections
Confirmation of Electrolyte
Specific Gravity (pilot cells) Refer to

Activation 5.1
Refer to
5.2
Electrolyte Replacement
Refer to

Capacity Test 5.3

Refer to
3.2.2)

10-
 4.2Inspection and Treatment
Perform the following inspection and have the
results recorded. If the result is OUisIde
andard, give proper redients according to the treatment column.
4) Monthly Inspection (Spontaneous Inspection)
Item Action
Total Battery Voltage
Read voltage by volt
During Floating
meter on front panel.
Charge
Confirm whether level is
Electrolyte Level within standard.
Appearance of Check for existence of
Battery leakage
(2) Six Month Inspection
Item Action
(1) Measure total battery
voltage by voltmeter
Total Battery Voltage
of class 0.5 or better.
During Floating
Charge (2) Calibrate the reading
of voltmeter on front
panel.
Voltage of All Cells
Measure voltage on all
During Floating
cells by voltmeter.
Charge.
Measure temperature of
cell expected to be
Battery Temperature highest from the
arrangement of cells.
Confirm whether elec-
Electrolyte Level trolyte levels of all cells
are within standard.
the
Standard Treatment
Floating charge voltage Adjust to standard value.
in Table 4 x No. of cells.
If level has fallen near MIN
Should be within range water up to
level, and purified
between MAX and MIN MAX line. After refilling with
levels. (See Fig. 19) purified water, give equalizing
charge.
When leakage is detected,
upon investigation of cause,
There should be no
give treatment at site if feasi-
leakage. ble. If infeasible, replace the
unit cells.
Standard Treatment
Adjust to standard value, if
voltage is outside standard.
Floating charge voltage
in Table 4 x No. of cells
If calibration is impossible,
replace voltmeter on panel.
If voltage is outside the stan-
dard, give equalizing charge
according to Item 4.3.(2), and
Voltage shall be within confirm by subsequent
range of +5% of values inspection. If still outside of
in Table 4. standard, give treatment
referring to attached
"Treatment Flow of Major
Troubles"
If ambient temperature
exceeds constantly 45°C, the
installation conditionis
15-30°C is preferred. judged inadequate.
Improvement of environmen-
tal conditions should be
made.
To be in range between Refill purified water to MAX
MAX and MIN levels. level, and give equalizing
(See Fig. 19) charge.
 Item
Action Standard

Check for such dam- t

Treatmert
any cell
1s
ages as cracks and ages on found with
deformation of contain- replace the cell.irnerIf and covedar
cont a
er and cover, and leak-
age.
found
determine thleae Cause
and if severe
cell. replace e unit
Check for damages on

Appearanceof
various plugs and gasS- Damaged parts shall be
Battery
kets. replaced.
Check for contamina Wipe off and
clean
tion by dust, etc. cloth. Dry cloth of by wet
textiles should not bechemical
used
Generation of rust on
cubicle, rack, connect
Clean and apply
ing, bars and wires and tive rust preven
treatment or painting
terminals.

Note: Small size voltmeter may be supplied as an optional item. This

for measuring unit cell voltage, and is not capable of
voltmeter is solelv
USed
the purpose of administration of the total
measuring the total voltaoeF
voltage and calibration of meters, a
voltmetsr
of class 0.5 is required. This voltmeter shall be
provided by the purchaser. For deter
mining the acceptability of unit cell voltage, the voltmeter of Class 0.5 should be used

(3) Yearly Inspection

For yearly inspection, the following items shall be added to those of six month
inspection.
Item Action Standard Treatment
-

Additional Tightening Give additional tighten In accordance with

of Connections ing to bolts and nuts. Refer to Item 4.3.(6).
Table 6.

4.3 Methods of Maintenance

(1) Floating Charge
The setting voltage values during floating charge
ues given in Table 4 across
the
shall be maintained
constanuyend1o
be battery terminals. If this voltage is too low, the Da
on
discharge side with reduced capacity which will not ensure
on f t00
high, the battery wil tend to be on satistactory
overcharge side which will not only accelaodectease 0 ed
electrolyte level but also shorten the battery life.

(2) Equalizing Charge

Once every six months
VIn

practice) given in Table 4. Beduring floating charge, give an C C o r d a n c e

to prevent the
sure to
give without fail the equalizing cnargce it is pUP
variations of characteristics of each cell. equalizing cnarg

12-
 Table 4: Floating Charge Voltage and
Standards for Equalizing and Recovery Charge
Battery Type
Floating Standards for Equalizing, Recovery Charge
Plate
Type
JIS Charge Voltage Equalizing Charge Charge Time After
Type Type (Standard Setting) Voltage (Standard Reaching Standard
QKC AM-P 1.44V
Setting Voltage) Setting Voltage
Pocket x No. of cells
Type QSC AMH-P 1.42V x No. of cells 1.58V x No. of cells
QFD AH-S
Sintered 8-12 hours
Type QFG AHH-S 1.36V x No. of cells
1.47V x No. of cells

(3) Recovery Charge

The recovery charge to
be given after dischargeis performed with the
enualizing charge. Charge
on the amount of previous method
time will same as
very
Completion of the charge shall be defermineddepending discharge.
by the following standard.
Determination of Charge Completion:
When 8 hours are elapsed after
setting voltage. (Refer to Table 4) reaching
standard

Upon completion of the

charge, the battery shall be returned to
mal operation. floating charge mode for nor

(4) Replenishment of Purified Water

When the electrolyte level is
dropped near MIN line during floating charge, refill
water up to MAX line. If charge is continued with purified
to atmosphere, it may cause the electrolyte level as low as to expose the plates
battery damage by burning. Never use battery with
to
depleted. Also be careful not to refill excessively electrolyte
above MAX level as it may cause an overflow.
(Refer to Fig. 19)

Excessive
Proper Refilling

MAX. Line
MIN. Line

Fig. 19: Electrolyte Level (During Floating Charge)

The purified water used shall be in accordance

with the of performance
Be careful that the use of impure water will result in reductionspecification
givencharacteris-
in Table 5.
tics and
shortening of battery life.

- 13
 Table 5: Specification of Purified Water for Alkaline Batteries (SBA4001)

Item Specification
Turbidity Less than 2 Deg
Hydrogen lon pH 5.8-8.6
Electric Conductivity Less than 10 us/cm
Chlorine ion Less than 0.0001%
Iron lon Less than 0.0001%
Sulfuric Acid lon Less than 0.0001%
Calcination Residue Less than 0.001%
Impurities
Potassium Permanganate Reducible Substance (0) Less than 0.005%
Calcium lon Less than 0.0001%
Silicon lon Less than 0.0001%
"Magnesium lon Less than 0.0001%

GS Yuasa specification

(5) Cleaning
Keep the battery and its surroundings clean and dry at all times. If a battery is used with
spilled electrolyte deposited on it, creeping current may flow or electrically conductive parts may
get corroded. For cleaning, use waste cloth wetted with water or warm water and squeezed tight
ly. Never use dry cloths (especially chemical fiber cloth) or "dusters" which are extremely danger
Ous for generating static electricity (which may ignite and explode the gas generated inside the
battery). Never use such organic solvents as paint thinner, gasoline, benzine and alcohol as they
cause cracks on cell containers.
Since terminal parts of connecting wires are susceptible to attach by electrolyte, apply thin
coat of rust-preventive oil such as vaseline after cleaning.

(6) Additional Tightening

Give additional tightening to the connections once every year during the service. Use torque
wrench referring to Table 5. Be careful not to generate short circuits with the tools used. To pre
vent short circuits, tie round vinyl tapes on tools used.

Table 6: Tightening Torque of Connecting Bolts and Nuts of Each Type of Batteries

Type and
capacity QKC QSC QFD OFG
Torque (AM-P) (AMH-P) (AH-S) (AHH-S)
N.m (kgt-cm)
10.0+1.0 (100+10) 30-80 20-80 20-150 20-100
13.0+1.3 (130+13) 100
15.0t1.5 (150+15) 100-900 200-450 120-350
17.51.7 (175+17) 500-1200 400-1000

20.0:2.0 (200-20) 120-200

23.02.3 (230+23) 250-1000

- 14
5.Special Maintenance
Specific Gravity Check
5.1
eire the specific gravity of the electrolyte once or so year and contirn
Mranae of 1.17 to 1.23 (20°C). This measurement musteverybe carried out under the co
withinhe electrolyte level is at MAX line and the electrolyte is well stirred with the assing gen
an equalizing
charge.
erated by
Cor temperature correction of the specific gravity, refer to Item 6.2.
For
4 the specific gravity a s found outside the above allowance, perform electrolyte replace-
f
ltem 5.3.).
ment (see

5.2 Activation
There may be a case of performance characteristics being reduced when the plates get
liahtly inactivated during continuous operation on floating charge mode (particularly when used
sligh In such a case, if repetition of charge and discharge is performed
in elevated temperatures).
will
iactivation), the battery restore nearly the original characteristics. As the standard method,
at 0.2C for 5 hours, and then charged at 0.2C for 15 hours (300%
the battery is discharged below 35°C.
charge). this case, the battery temperature must be maintained
In

5.3 Electrolyte Replacement

of the following conditions is encoun-
be carried out when one
Electrolyte replacement shall
tered.
decreased at 6 to 8 years of service.
(1) battery capacity is abnormally
When the
materials are introduced into battery.
(2) When any impurities of foreign
carbonate (K2CO3) in the electrolyte
reaches more than 90
Or amount of potassium
g/2 (value permitted by our company).
outside the standard value.
(3) When the specific gravity is the following sequence.
shall be performed in
The electrolyte replacement
the cut-off voltage of
discharge. (See to Fig. 2)
(a) Discharge the battery to disposition of the drained
elec-
side down and drain the electrolyte. (For
(6) Turn the cell
trolyte, refer to Item 10.)
(c) Fill in fresh electrolyte
accordance with Item 5.2.
Give activation treatment in
() in accordance with Item 3.2.(2).
test
performing capacity
e Verify the capacity by the electrolyte again.
in the capacity test, replace
At the end of discharge re-use.
the battery and
(9 Fully charge

-15
6. How to Use Maintenance Tools
(1) Small Size Voltmeter (supplied as an optional item)
Small size. portable type voltmeter may be supplied. The scales are either 0-3V or
-3v-OV-+3v, used tor measuring unit cell voltage. (Be careful that this voltmeter can not be
used for measuring the total battery voltage.) To make measurement, place the measuring tip
provided at the lower part of voltmeter onto negative terminal of the battery cell, and the lead-wire
terminal tip connected to the measuring terminal provided on the top of voitmeter onto positive
terminal of the battery cell, as shown in Fig. 20.

Fig. 20: Measurement by Voltmeter

(2) Syringe Hydrometer

Syringe hydrometer is supplied with measuring outer cylinder, rubber ball and float being
float into the outer cylinder in the sequence as
separately packed. Assemble it by inserting the
shown in Fig. 21.
Rubber Ball

Hydrometer (Float)

Measuring Outer Cylinder

Fig. 21: Sequence of Hydrometer Assembling

To make measurement by syringe hydrometer, remove the filling plug of a cell, grip tightly
the rubber ball, insert the suction tip into electrolyte somewhat deep, and then release the grip
The electrolyte will come into the cylinder as shown in Fig. 22. Wash with water after use, and
store.

Fig. 22: Measurement by Syringe Hydrometer

- 16-
 Read the scale at the highest point of the
iquid which swells up due to surficial ten-
shown in Fig. 23.
sion as

hydrometer
areful that the
Jch the inside float does
wall of outer
Eye Position
not
at this time.
cylinder
The specific gravity of electrolyte varies Electrolyte
(Pdeoending on temperatures. Therefore
specific gravity measurement should Hydrometer Float
always be accompanied with tempera-
ture measurement to correct it to the
standard value at 20°C Correction shall
be done by the following formula. Fig. 23: How To Read Hydrometer
D20 D+ 0.0005 (t20)

where,D2o: Specific gravity corrected to 20°C

D: Specific gravity attrC
t:Temperature at actual measurement
() Rod Type Thermometer
Alcohol filled rod type thermometer is used. To use unplug the filling plug of a cell, put the
thermometer into the electrolyte, leave for about thirty seconds, and then read. Being made of
glass, be careful in handling not to break.

(4) Jug, Funnel and Filling Syringe

All are made of plastics, used for lling electrolyte or water replenishment. Use jug and fun-
nel tor handling relatively large volume of liquid (Fig. 24), and filing syringe for small volume (Fig
25).

Rubber Glove
Funnel

Jug

Purified Water
Fig. 24: Filling
Syringe
Rubber Glove
Suck Liquid

FillLiquid

Syringe
Filling
To Use
Fig. 25: How

- 17
 Tool
Tightening
Terminal
(5) removing of connecting parts of
This is used for tightening and
to prevent short
circuit.
a

battery Bes
h.

tool will
not be left on battery sUre hat hos
(6) Tools Box
of plastics is used for housing the maintenane
enance appliance (1
The box being made

- 18
7. Cautions
Prohibition on Fires
(1) Strict
Since the storage battery generates constantly during charge inflammable hydrogen gas,
drawn near.
there is a risk of ignition and explosion if sparks or ires such as lighted cigarettes are
in the battery room. Provide always good ventilation in the battery room.
Never usoe fires

(2)Prevention of External Short Circuits tightening screws and

Be caretul not to make short circuits at the battery with tools used for
nuts.

(3) Precautions on Electrolyte Depletion the

to expose the plates to atmosphere,
If charge is continued with electrolyte level as low as
with damage by during. Never use a battery with electrolyte depleted.
battery may be caused
Acid
(4) Strict Prohibition of Sulfuric alkaline storage
water shall be kept exclusively for
The maintenance appliances and purified Mixture of sulfuric
with lead-acid battery should be avoided at
all times.
battery. Common use maintenance tools than those
shorten the life. Never use other
acid will damage the battery and
supplied with th battery.

(5) Cautions on Handling Electrolyte or clothes may

eyes, mouth, skins
being solution of caustic potash
on
Deposits of electrolyte with liberal amount of fresh
water. If
cause severe burns or loss of eyesight. If deposited, wash
entered in eyes get immediate medical attention.
and rubber
such as protective eye goggles
When handling electrolyte, protective appliances be taken. The electrolyte is highly
shall be provided and their advantages should always
gloves it off immediately.
on the rack or floor. If spilled, wipe
corrosive be careful not to spill it

Electric Shocks
(6) Cautions on touches electrically conductive parts
danger to electric shocks when one
There is always a with bare hands.
and connecting bars. Never touch these parts directly
Such as battery terminals
Static Electricity
(7) Cautions on (especially chemical fiber
Never use dry cloths
In cleaning battery, use only wet waste cloth. dangerous (may
static electricity which is extremely
cloths) or "dusters" as they wll generate
from battery). Use waste cloth wetted with water
or warm

ignite and explode gases generated

water and squeezed tightly.
Solvents
(8) Strict Prohibition of Organic develop cracks if it gets in contact with such
The container being made of plastics may Never use these organic sol-
benzine and alcohol.
organic solvents as paint thinner, gasoline,
vents for cleaning the battery.

(9) Battery Temperatures is -20°C to +45°C.

vented type alkaline batteries
range for
The permissible temperature in shortened lite, and use in low temperatures in
Use of battery in high temperatures will result of 1.20 at
of electrolyte (standard specific gravity
reduced capacity. The freezing temperature to freezing during storage. The optimum bat-
20C) is-27°C. Be careful not to bring the battery
tery temperature during use is 15°C 30°C
(10) AC Ripple Current
the
Be careful that battery tempe ature may rise if the AC ripple current superimposed
on

charge current exceeds 0.2C during floating charge

(11) Shutdown of Charger Operation
Shut down the charger operation when to perform battery discharge test, additional tighten-
when the battery has been dis-
ng or
connections, reactivation and electrolyte replacement (only
charged).

19
8. Trouble Shootingg and
maintenance of aline storage batter.
alkaline

at inspection Table 7 belowv.

d e s c r i b e d in the
appear
which may are
phenomena treatments
On causes
and
presumptive
ies, their
Alkaline Batteries
Trouble Shooting of
Table 7:

Presumptive Cause Treatment

Phenomena
Item
(1) Incorrect setting (1) Adjust charger for setting value.
Floating voltage (total
low (or too
voltage) is too
(2) Failure in charger (2) Check and repair charger
high).

(1) No equalizing charge has been (1) Perform equalizing charge

given.

Particular cells have volt- Internal short circuit (2) Replace cells in question.
(2)
age too low.
(3) Apply life diagnosis and replace
(3) Deterioration due to aging
cells in question or all cells.

(1) No equalizing charge has been (1) Perform equalizing charge.

given.

(2) Temporary inactivation (2) Perform activation charge.

Too large variance
among individual cells.
(3) Degradation of electrolyte (3) Replace electrolyte and give acti-
(increase of K2C03). vation charge.

(4) Deterioration due to aging. (4) Replace all cells.

(1) Floating voltage is too high. (1) Adjust charger for setting value.
Electrolyte decrease has (2) (2) Apply sufficient air conditioning
become quicker. Ambient temperature is too high. or ventilation.
(3) Cells internally short circuited are (3)
included. Replace cells short circuited.

(1) Insufficient ventilation. (1) Improve ventilation.

Temperature of all cells
in higher than room tem-
(2) Floating voltage too high. (2) Adjust charger for setting value.
perature by more than
5°C. (3) Cells internally short circuited are
included. (3) Replace cells short circuited

(4) Superimposition of AC content. |(4) Investigate powersupply and

reduce.
(1) Internal short circuit.
(1) Replace cells in question.
Temperature of
cells too high. particular (2) Insuficient tightening at terminal
Connection (2) Give additional tightening9
(3) Heat source is located
nearby. (3) Improve environment.

- 20