INSTALLATION AND COMMISSIONING PROCEDURE

FOR

EXIDE PLANTE′ TYPE

STANDBY BATTERIES

COMPLETE WITH FIRST CHARGE INSTRUCTIONS AND

MAINTENANCE PRACTICE

Rev-02/Oct22
CAUTION :

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

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

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.

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 the battery. Before working ona
battery, always remove personal metal effects, such as rings, watches, bracelets,
necklaces, etc.

ALWAYS PROTECT THE EYES.

 1. Loading / Unloading & Handling:
Exide Plante cells are generally dispatched from factory in packed condition. Care should be taken
during loading/unloading of the cases/pallets on/from the trucks. It should preferably be done with forklifts
or suitable mechanical means, avoiding pressure on the sides. Cases should never be dropped or
subjected to jerks. It should not be tilted or kept on its sides. Rough handling can damage the cells and
other materials.

2. Storage & Preservation:

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

The cases / pallets having cells or accessories are to be stored in dry and cool 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 covered place avoiding
chance of mechanical damage.

3. Unpacking / Handling:

Care should also 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. Careshould be
taken in handling the cells and other components to avoid damage. The cells are 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.
Request for 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.

Store the cells (with the vent plugs screwed on firmly), and other accessories in a dry, cool and
dust fee covered place.
 4. 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. 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 best performance when working at room temperatures of 20 deg C to 35
deg C. It will also function satisfactorily when operating at temperatures between 5 deg C to 50
deg C (intermittent). Higher temperatures increase the battery capacity, but decrease the life of
the cells. It is therefore preferred that the battery room temperature is kept below 40 deg C in
order to ensure trouble –free operation of the battery for a long and useful service life. 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 is 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. Alternatively acid proof paints are to be provided which would require
periodic renewal.

Proper exhaust fans should 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 room. The exhaust calculation can be available from the Generals
Technical Particulars 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 case of naked flames
or 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.

5. Power Requirement
A D.C supply capable of delivering the constant current specified in the technical specifications
will be required. The voltage required for initial charging is about 3 times the number of cells in
the battery bank, i.e. charger has to be designed for 3 volts per cell. This is required to charge
the battery banks at 12-14 Amps DC Constant Current (Starting rate) up to 2.36 vpc and 6-7
Amps DC Constant Current (finishing rate) up to 2.75 vpc per 100 Ah (C10 capacity) battery bank.
 6. 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 is easily accessible for inspection, maintenance etc.

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

7. 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 14 Amps DC per 100 Ah C10 capacity
of the battery to start with and 7 Amps DC per 100 Ah C10 capacity of the battery at the finishing
stages of charging. The charger should be capable of providing 7% 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 2.24 to 2.30 volts per cell. For equalizing charge, the charger shall be capable of
supplying 3 Amps DC (constant current) per 100 Ah C10 capacity ofthe battery.

Charger output or load induced current ripple can cause permanent damage and a
reduction in battery life. Under float condition, with no load, the maximum ripple current
allowed shall be less than 5% of rated capacity RMS of set (recommended) trickle current.
Consequently, it is recommended that voltage ripple under float condition, with no load,
shall not exceed 1% RMS of the set float voltage.

8. Polarity of Charging Leads

It is of utmost importance that the positive terminal of the battery is connected to the positive lead
of the charging source and the negative terminal with the negative lead of the charger.
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
 9. Acid / Battery grade Water

i) The acid to be used in the battery for initial filling is battery grade Sulphuric Acid
(H2SO4)of specific gravity 1.205 + 0.005, at 270 C, conforming to IS: 266 - 1993. This
is normally supplied with the battery.

ii) Battery grade water (distilled or demineralised) should conform to IS:1069 - 1993 for
topping up of cells.

iii) If the acid is obtained in concentrated form, it is necessary to dilute it to 1.205 Sp. Gr.
The acid as well as the distilled/DM water to be used for diluting the acid should
conform to Indian Standard Institution specification IS: 266 – 1993 and IS: 1069 – 1993
respectively.

(iv) Caution:

1. All jobs should be done under supervision of authorised personnel only.

2. Clean vessels of hard rubber, plastics, porcelain or lead-lined MS tanks/ wooden boxes
only should be used for storage and handling of acid and distilled/ DM water. Do not use
metal vessels other than lead.

3. When working with acid or electrolyte, always use protective goggles, rubber gloves and
rubber apron.
4. Keep ready Bi-carbonate of Soda solution or 5% to 10% Ammonia solution to take care
of accidental spill / splash of acid on skin, eyes or garments. Remove garment
immediately, neutralise spot with 5 to 10% ammonia or soda solution and wash thoroughly
in water. On skin / eyes, flush with large quantities 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 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.
10. Temperature Correction

The specific gravity of the electrolyte varies with temperature. Any reading observed on
the hydrometer should therefore be corrected to 27 0C as all the specific gravity values
indicated by us are at 270C.
The correction should therefore be made as follows :
For every 10C above 270C add 0.0007 to the specific gravity as read on the hydrometer.
Similarly, for every 10C below 270C subtract 0.0007 from the specific gravity as read
from the hydrometer.

11. 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 easy support and
keeping the passage in between clear. This is desirable for easy access to the cells
for allowing easy removal of cells for service attention, whenever required.
d) The positive end of the battery has to be connected to the positive output 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 have sufficient 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 and the floor.
Arrange cells in such a manner that the positive terminal lug of one cell adjoins the
negative terminal lug of the next cell throughout the battery. Use a wooden spacer to
ensure even spacing out of cells. No cell insulator is required for Plante Cells.

For Seismic stands no Stand/ Stillage Insulator required as these are grouted 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 of each terminal pillar with
petroleum jelly and tighten the bolt connectors firmly using two spanners, one onthe
bolt head and one on the nut.

Note particularly that the positive terminal of one cell is connected to negative terminal of
the next cell throughout the battery leaving the positive terminal of the first cell and
negative terminal of the last cell of the battery bank free for connection to the charging
source. Finally, check again that the cells are connected in the correct sequence.
Charging a cell of the whole 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 positive terminal 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 rows may be made with the necessary length of
copper rod or bar or cable of the size used between the switchboard and the battery.

Each end of the copper rod/ cable (For YKP & YAP) is soldered into the socket of the
cable-ends provided or crimped type flexible cable connectors, the ends of the latter being
bolted on the terminal lugs of the battery. For YHP range copper bars/ crimped cable ends
for flexible connectors are used.

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. Alternatively,
heat shrinkable PVC tube of sufficient length is to be inserted on the cable before the
crimping is done. This tube will grip the uninsulated end of the cable and cable end when
heated with a hot air gun and thus will create an insulation layer at that point.

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.

(iv) Connecting to charger :

Connect positive terminal of the battery to the positive lead of charging source and
negative terminal of the battery to negative lead of the charging source 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 be available at
the site for the initial filling of the cells. The sulphuric acid should be 1.205 +/- 0.005 Sp.
Gr. (at 270C ).

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. 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 10-12 hours. The plates will absorb
the electrolyte and the electrolyte level will drop. Restore the electrolyte level at the end
of this 10-12 hours period by adding more acid of 1.205 Sp. Gr.

After filling in all the cells, following are to be ensured prior to commencement 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.

Initial charging must commence within 24 hours of electrolyte filling & it is therefore
essential to ensure that the charger is in proper working condition priorto electrolyte
filling of the cells.

12. First Charge

(i) Charging Equipment

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

(ii) Connections – Polarity

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.

(iii) First Charge

Commence charging 12 hours rest, but not later than 24 hours after filling in the first cell
with acid. The initial charging can be initiated by (a) Starting rate (first portion) &
followed by Finishing rate (second portion) or

(b) Finishing rate throughout till completion of charging.

(iv) First Portion

The first portion of the charge should be given at any rate between the starting 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 (gassing voltage) per cell.
 (v) Second Portion

The second portion of the charge must be given at the finishing rate as mentioned in the
relevant technical particulars. This stage should continue till either the signs of completion
of charge as described in clause 12(vii) are observed or the minimum Ah input required
(as mentioned in the relevant technical specification) is administered, whichever
happens later.

OR The charge must be given at the finishing rate as mentioned in the relevant technical
particulars. This should continue till either the signs of completion of charge as described in
clause 12(vii) are observed or the minimum Ah input required (as mentioned in the relevant
technical specification) is administered, whichever happens later.

This is very important for the life of the battery that the first charge be administered very
carefully so far as the minimum Ah input and signs of full charge are 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 the state of charge
of the whole battery.

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

a. Specific Gravity,

b. Voltage, and
c. Temperature

Till the cells are fully charged

(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 will begin to rise slowly and
continue to rise throughout the charge until finally it ceases to rise and
remains constant. The charge should be continued until the specific gravities
have attained constant values for three (3) successive hourly readings in all
cells.

b) Voltage : The cell voltage at the beginning of the charge will be a little over
2 volts and will rise during the charge finally attaining a steady value. This
value, commonly known as Top of Charge (TOC) voltage, may reach upto
2.75 volts per cell at the finishing rate of charge, depending on the
 prevailing electrolyte temperature, which, when higher than 27 ˚C, tends to
depress the voltage slightly from the ideal top of charge.

c) Gassing: The reduction of current during charge, as mentioned above, is

to limit the amount of gassing, but at the end of the charge all the cells should
gas freely and vigorously. If any cell fails to gas or is late in gassing or if
it‘s gravity is lower than that of other cells, it should be closely examined to
find the cause. When found and corrected, the charge should be continued
until the cell is brought upto the fully charged state like the others.

d) Colour of plates: The positive plates should assume a full rich chocolate
colour and negatives a smooth light gray when fully charged. This can be
observed in transparent containers only.

e) Minimum Ah Input – Please keep track of total Ah fed into the battery and
ensure, minimum Ah input, as mentioned in technical particulars, is given
to the battery.

When all the signs of completion of charge are observed, and the minimum Ah input
required (as mentioned in clause 12(vii) is administered, the charge should be terminated.
After about one hour, 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 50 0C. Suspend
the charge if the temperature reaches 500 C and resume charging after the battery has
cooled to about 400C. If necessary, slightly lower the recommended charging rate in
case of very high ambient temperatures.

Where ambient temperature is 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.

(viii) Electrolyte Level

Maintain the level throughout charging adding 1.205 Sp. Gr. Acid if necessary.

(ix) Adjust Specific Gravity of Each Cell

If at the end of the first charge, the specific gravity of the electrolyte exceeds 1.215,
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 1.215 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.
 Never make an adjustment on cell which does not gas on charge.

Final specific gravity should be 1.215 +/- 0.005 at 27 ˚C in all the cells. It is very
important to adjust the specific gravity correctly so as to ascertain the state of
charge and state of health of the battery properly during its entire service life.

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

13. Capacity Test : C10 discharge

i. After a rest of 12 hours from the time the charging is switched off, the battery
shall be discharged at C10 current for 10 hours. The end of discharge voltage at
the end of 10 hours is to be noted. The temperature and specific gravity readings
are to be noted for the entire length of discharge for the pilot cells. End of 10
hours the cell voltage shouldn’t go below 1.85 volts.

ii. The discharged bank should immediately undergo recharge in the constant current
mode. The charging to start at the “starting rate” as mentioned in the product
catalogue for the respective size till the voltage reaches 2.36 volts percell
followed by charging at “finishing rate” pertaining to the specific size of the battery
as mentioned in manufacturer’s catalogue. The charging to be stopped when the
cell voltage and specific gravity readings are constant for three consecutive hourly
readings.

iii. The expected end-of-charge voltage is upto 2.75 volts per cell. During rechargingit
has to be ensured that a minimum Ah input of 125% of the previous discharged Ah
is administered to the battery. The temperature during charging should not increase
beyond 500 C. In such cases, the charging to be stopped and the cells to be
allowed 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 be compensated accordingly to
ensure that the minimum Ah input requirement is fulfilled.

iv. After the charging is over, specific gravity and electrolyte level of all the cells are to
be adjusted to specified values.

14. Final Readings/ Record Book

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.
 15. 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.

16. Putting into service

After cleaning up the cells clean and dry, secure all connections and re-apply the
petroleum jelly on the connectors, pillars, bolts, nuts and washers. Clean up any acid
which may have dripped or spilled on the cells, stand or the floor.

Check that the specific gravity of the electrolyte in all the cells is fairly uniform and of
correct value i.e. between 1.210 to 1.220 at 27˚C and the level of the electrolyte is at the
Max line in the cells. The battery is then ready for service. It is important to operate and
maintain the battery in accordance with the instruction provided in the interest of trouble
free operation throughout its service life.

At installations where the battery is likely to be on float for prolonged periods without
discharge, it is preferable to carry out 2-3 charge/discharge cycles before putting the
battery into service. However, for acceptance criterion if the obtained capacity in 1 st
discharge is 100%, further cycle is not required. Additional charge-discharge cycles are
not a mandatory part of IFC activities but can be carried out on extra charges on request.

17. Storage

If the battery is to remain unused for 2 to 6 months after commissioning, give an extended
charge at least once every month. Keep plates covered by adding puredistilled water to
the prescribed level. Before using the battery again, give it an extended charge until the
hydrometer shows a constant specific gravity reading for 3 hours.

18. 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.
(ii) Adjust/check Float/Trickle charge current to the required value as per instructions
given by the manufacturer.

(iii) The Float / Trickle charge should be adjusted to give an optimum battery voltage of 2.25 – 2.27
volts per cell based on the ambient temperature as per the chart given below :

Temperature Float Voltage

<50 C 2.30  0.02 vpc
50 C – 190 C 2.27  0.02 vpc
200C – 350C 2.25  0.02 vpc
360C – 450C 2.23  0.02vpc
(iv) Additional Information : All specific gravity’s referred to above are at 270 C.
Additional information/ clarification if required can be obtained from the nearest office of
Exide Industries Ltd at the addresses shown on the outside back cover.

NOTE ON BATTERY CHARGING

Constant Potential Charging – on Service:

The proper operation and correct adjustment of the charging supply ensures trouble-free
operation and long life of the battery. It determines the rate and amount of charge received and
thus indirectly its topping-up requirements.

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 that is necessary is
furnished, the battery life will be shortened. It is therefore highly important than the charging is
proper for the life and proper 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 2.25 vpc. Under these conditions of constant
voltage charging, the battery regulates its own charging current.

However, to protect the charging source from overload, an adjustable series resistance is
installed to limit the current with a discharged battery.

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 Trickle Current.

The value of the charging current, therefore, gives a rough indication of the state of charge, if
charging voltage is maintained as per the recommended float voltage.

Charging voltage:

This is controlled by means of suitable regulators. Under ordinary conditions, voltage should be
adjusted between 2.24 to 2.30 volts per cell – the exact value depending upon the ambient
temperature of the installation. When properly adjusted, the charger shall bring the battery to a
fully charged condition promptly and then furnish only the current to maintain it fully charged. It
is, therefore, very necessary that the voltmeter used is accurate. Any deviation from the standard
setting should be corrected immediately as a very small variation in voltage, produces a large
variation in current.
Correct adjustment of the Float Charging rate ensures:

a) Proper amount of charge without possibility of overcharge.

b) Minimum water consumption.
c) Safe limits of operating temperature and less corrosion.
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 resulting in operational failure.

b) Possible damage to the battery due to over-discharge and stoppages for repairs.
c) Shortened life.
d) Corrosion due to weak acid

Specific gravity is an indication of the state of charge of a flooded lead acid battery. In the fully
charged condition, the specific gravity of the battery would read as 1.215  0.005 measured at
27C. A higher specific gravity every time would indicate that voltage setting is too high, due to
excessive water loss and a lower specific gravity would indicate that the battery is not receiving
sufficient amount of charge. When temperature of the electrolyte differs from the standard
temperature of 27C it is necessary to correct readings of specific gravity observed on the
hydrometer to the equivalent specific gravity at 27C.

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 (usually 3 to 4% of the rated capacity of cells) given in order to
bring all the cells in the battery bank to a healthy state.

“Equalising Charge” is to be administered to a battery bank standing on constant current 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 7A DC per 100 Ah C10 capacity to the top of charge voltage upto 2.75 V/Cell till 3
consecutive hourly readings of cell voltages are observed to be constant. This is to be followed
by a further charge at a constant current of 3A DC per 100 Ah c10 capacity for a period of 12- 16
hours. At the completion of this charge the battery bank may be put back on float.
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 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.
 BATTERY MAINTENANCE
Routine maintenance must take into account of the following factors and include maintaining
proper record of critical parameters, 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, and particularly the
time interval between the inspections, these should be made initially at short intervals of a
week or so and the results carefully logged and reviewed on 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 a partially discharged
battery would not be a very reliable source of power in case of emergency.

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

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.

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 IS 1069 (Latest
Revision), to keep the electrolyte at the correct level.

d) Take particular care, avoid short circuit by bridging the terminals with spanner 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’ at constant current as recommended, on periodical basis.

h) Do not exceed “ finishing” rate”, when cells are gassing.

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 maintenance of battery are
listed below: -

a) Digital Multimeter: To enable voltage readings of individual cells as well as total

battery and main source voltage a suitable digital multimeter/ voltmeter should be
used. It should be calibrated at regular interval or should be compared with a
standard meter periodically to ensure accuracy.

b) Syringe Hydrometer: A clean and accurate syringe hydrometer suitable to read

specific gravity readings from 1.100 to 1.300 should be used.

c) Thermometer: An accurate thermometer of 0C to 100C range should be used

to read the electrolyte temperature.

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

MAINTENANCE SCHEDULE

The maintenance schedule given here is divided in daily, fortnightly, monthly, quarterly, half-
yearly and yearly maintenance.

DAILY MAINTENANCE

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

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 out of every 60
cells to be chosen as pilot cells.
MONTHLY MAINTENANCE

A monthly maintenance should include all the items mentioned in “daily maintenance”
and the following :

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

2. Visually check the conditions of each cell and battery bank. Any abnormality
observed to be immediately noted and observed for next 15 days.

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

4. Check condition and tightness of all vent plugs and connectors. Clean all the cells
with dry cloth to wipe out any dirt or dust accumulated on the vent plugs.

5. Check electrolyte level in all the cells and note. Plante cells are not expected to
show much of a water loss in a month but any abnormal drop in electrolyte level
should be noted and cause to be investigated.

6. Visually inspect all the cells for sediment level and colour of plates. Any abnormality
found to be immediately brought to the notice of concerned people.

QUARTERLY MAINTENANCE

A quarterly maintenance shall include all checks listed under “daily”, and “monthly”
maintenance schedule and also the following :

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

2. For a battery bank, unless it has undergone a discharge within previous 24 hours,
the electrolyte temperature should lie within 3 – 5 deg. C of the corresponding
ambient temperature. In case of a deviation from this range, the charger needs to
be checked for its quality of power output in terms of the ripple contents in the
charging voltage and current. Corrective action should be immediately taken to
avoid any deterioration in the battery bank due to this anomaly.

3. The voltage and specific gravity data of all the cells from the previous fortnightly
data sheets are to be observed. If any cell/s shows different readings compared
to other cells in the bank, this/these cell/s should be watched and monitored
separately. Readings of such lagging cell may be recorded and analyzed with pilot
cells.
HALF YEARLY MAINTENANCE

A half yearly maintenance shall include all checks listed under “daily”, “monthly” and
“quarterly” maintenance schedule and also the following :

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

2. Retighten all the electrical connections between the cells and between battery bank
and charger to the prescribed torque value. This would ensure properconnection
and operation with the minimal loss of electrical energy.

3. Plante cells shall, normally, not require any topping up at this stage. However, in
case any cell shows an abnormal drop in electrolyte level, top up with battery grade
DM water. The cell needs to be observed for other manifestation of abnormality like
higher than normal temperatures, high corrosion in the plates etc. The cell may
require special investigation and analysis if this becomes a repetitive phenomenon
for the particular cell. Do not use metallic vessel for topping-up as this may
contaminate the water and would run a risk of creating an accidental short
circuit.

YEARLY MAINTENANCE

A yearly maintenance should include all items listed under ‘daily’, ‘monthly’ and ‘’Qtrly.’
maintenance schedule and also the following :

1. Isolate the battery bank from the load. This would require matching the 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 current mode at acurrent of
7% of the rated C10 capacity of the bank ( 7 Amps per 100 Ah). The battery bank
is to be charged till all the cells are gassing freely and the voltage and specific
gravity readings of pilot cells have become constant over 3 to 4hourly readings.
The charging however should run for a minimum period of 5 hours even if the fully
charged conditions are achieved before that. The specific gravities and electrolyte
levels of all the cells are to be measured and to be adjusted with DM water to
specified values 4 hours after the charging is switched off. The electrolyte level
should remain near the maximum mark. After the adjustment the bank is to be
charged again for 1 hour at the same current to enable proper mixing of electrolyte
and DM water.

3. After a rest of 12 hours from the time the charging is switched off, the battery
shall be discharged at C10 current for 10 hours. The end of discharge voltage at
the end of 10 hours is to be noted. The temperature and specific gravity readings
are to be noted for the entire length of discharge for the pilot cells.

4. The discharged bank should immediately undergo recharge in the constant current
mode. The charging to start at the “starting rate” as mentioned in the product
catalogue for the respective size till the voltage reaches 2.36 volts percell
followed by charging at “finishing rate” pertaining to the specific size of the
 battery as mentioned in manufacturer’s catalogue. The charging to be stopped
when the cell voltage and specific gravity readings are constant for three
consecutive hourly readings.

5. The expected end-of-charge voltage is upto 2.75 volts per cell. During charging it
has to be ensured that a minimum Ah input of 125% of the previous discharged Ah
is administered to the battery. The temperature during charging should not increase
beyond 450 C. In such cases, the charging to be stopped and the cells to be
allowed 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 be compensated accordingly to
ensure that the minimum Ah input requirement is fulfilled.

6. After the charging is over, specific gravity and electrolyte level of all the cells are to
be adjusted to specified values.

7. The battery bank, then, is to be given an equalising charge at a current equivalent

to 3% of rated C10 capacity for 12-16 hrs.

8. The battery bank can be given back to the system after the equalising charge is
over, followed by adjustment of specific gravity, if required.

EMERGENCY INSPECTION

If any failure or problem is experienced or reported, carry out 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) Note 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) Note 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 to have low voltages, note their voltage on load and if it is
very low compared to other cells, which is probably the immediate cause of trouble, rectify
the low voltage cells or replace it with spare cells to put the battery back in service quickly.

OVERHAULING

A Plante battery bank may require one overhauling operation in its life time, usually not before
8 – 10 years of constant operation on float. The procedure is required essentially to take care
of accumulated sediments, replacement of worn-on components, if any, likely to develop due to
specific operating condition. Any such observation during visual checks should immediately be
brought to the notice of the manufacturer for suitable guidance.
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 should be selected for storage space.
Keep them with vent plugs firmly fitted in its position.
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. High
temperature will increase the frequency of such charges.
b) Charging: When charging is required, use the finishing rate. Continue charging until
free gassing occurs. Charging should not be suspended until specific gravities
(corrected for temperature) of majority of the cells have risen to the maximum and
have shown no further rise for three consecutive hourly readings.

ADVICE AND INSPECTION :

It is of utmost importance to Exide Industries Ltd that our customers get trouble-free long service
life from our products. The company is ready to provide all supports and assistance to its valued
customers on various issues related to the battery banks in use. Requests for such assistance
should be addressed to the Head – Service & Applications (Infra)., Exide Industries Limited,
91, New Chord Road, Athpur- 743 128, Shamnagar, 24 Pgs. (North), West Bengal
Email: uttamkp@exide.co.in giving complete details of the battery.
TECHNICAL DATA FOR PLANTE CELLS

Capacity at Total Min. Input Apprx. Qty

Approx qty of Corresponding cell Trickle Charge
Type of Charging Current of acid 1.205 Overall Cell Dimensions
10 Hrs rate during Initial Weight of cell +/- 5 % (KG) acid 1.19 sp centres Current
Cell (A) sp.gr. +/- 3 mm
(Ah) Charging (Ah) gr(Ltrs.)
(Litres) (mm) (mA)
Starting Rate Finishing Rate Without Acid With Acid Length Breadth Height* Min Max
YAP
YAP5 16 2 1 88 2.7 4.7 1.7 114 133 260 123 10 30
YAP7 24 3.4 1.7 132 3.5 5.4 1.6 114 133 260 123 15 45
YAP9 32 5 2.5 176 4.3 6.1 1.5 114 133 260 123 20 60
YAP11 40 6 3 220 5.4 8.8 2.9 190 133 260 199 30 90
YAP13 48 7 3.5 264 6.9 9.5 2.8 190 133 260 199 40 120
YAP15 56 8 4 308 7 10.2 2.7 190 133 260 199 45 135
YAP17 64 9 4.5 352 7.8 11 2.6 190 133 260 199 50 150
YKP
YKP7 75 10.5 5.25 413 10.5 18.2 6.5 173 203 426 211 60 180
YKP9 100 14 7 550 13.5 21 6.3 173 203 426 211 80 240
YKP11 125 18 9 688 27.25 22.4 5.8 173 203 426 211 100 300
YKP13 150 21 10.5 825 18 24.4 5.4 173 203 426 211 125 375
YKP15 175 24.5 12.25 963 19.7 28.7 7.6 210 203 426 211 140 420
YKP17 200 28 14 1100 22 30.7 7.3 210 203 426 211 160 480
YKP19 225 32 16 1238 24.3 34.9 8.9 248 203 426 211 180 540
YKP21 250 35 17.5 1375 26.7 36.9 8.6 248 203 426 211 200 600
YKP23 275 38.5 19.25 1513 29.1 41.4 10.3 286 203 426 211 220 660
YKP25 300 42 21 1650 31.5 43.4 10 286 203 426 211 240 720
YKP27 325 46 23 1788 36.3 52.6 13.7 362 203 426 211 260 780
YKP29 350 49 24.5 1925 38.5 54.4 13.4 362 203 426 211 280 840
YKP31 375 52.5 26.25 2063 40.8 56.4 13.1 362 203 426 211 300 900
YKP33 400 56 28 2200 43.2 58.4 12.8 362 203 426 211 320 960
YKP35 425 60 30 2338 45.6 60.4 12.5 362 203 426 211 340 1020
YHP
YHP11 535 75 37.5 2943 64.3 96.7 27.1 230 368 682 238 300 600
YHP13 645 90 45 3548 74.8 105.4 25.7 230 368 682 238 360 720
YHP15 750 105 52.5 4125 89.3 170.6 64.6 433 368 682 376 420 840
YHP17 860 120 60 4730 104.1 179.5 63.3 433 368 682 376 480 960
YHP19 965 135 67.5 5308 114.4 188.2 62 433 368 682 376 550 1100
YHP21 1070 150 75 5885 124.7 196.9 60.7 433 368 682 376 600 1200
YHP23 1180 165 82.5 6490 135 205.7 59.4 433 368 682 376 660 1320
YHP25 1285 180 90 7068 145.3 214.4 58.1 433 368 682 376 720 1440
YHP27 1395 195 97.5 7673 155.6 220.8 54.8 433 368 682 376 780 1560
YHP29 1500 210 105 8250 165.9 229.6 53.5 433 368 682 376 850 1700
YHP31 1605 225 112.5 8828 181.7 261 66.6 509 368 682 376 900 1800
YHP33 1715 240 120 9433 192 269.6 65.2 509 368 682 376 960 1920
YHP35 1820 255 127.5 10010 202.3 278.3 63.9 509 368 682 376 1025 2050
YHP37 1930 270 135 10615 215.9 307.3 76.8 585 368 682 376 1100 2200
YHP39 2035 285 142.5 11193 225.9 315.7 75.6 585 368 682 376 1150 2300
YHP41 2140 300 150 11770 236.2 324.4 74.1 585 368 682 376 1200 2400
YHP43 2250 315 157.5 12375 246.6 333.1 72.7 585 368 682 376 1250 2500

*Tolerance for Overall Height: +/- 5 mm

Ah output as percentage of 10 hrs capacity when discharging in :

Rev-02/Oct22