Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
Corporate Overview
Manufacturing
Accreditations
Financials
Social Responsibility
Battery Recycling You are here: Home > Industrial > Battery Servicing > Servicing Tips
INDUSTRIAL
Application & Products The ways & means to increase the life and performance of lead-acid batteries
Battery Sizing The most important part is the care during initial filling and charging which determines the life & performance and knowledge about how a
lead-acid battery works.
Post An Enquiry Followed by proper and regular routine and preventive maintenance of the battery banks.
To take corrective measures, one must have the knowledge of the normal failure modes of lead- acid batteries & the reasons for the failure.
Battery Servicing
If any one is conversant of the failure mode and the reason for same, then will be in a position to rectify / prevent before it is too late.
Locate a Dealer Initial filling & charging (IFC)
http://www.exide4u.com/exide/JSP/masters/Batteryservicing/ser_tips.htm 8/28/2012
.: EXIDE :. BATTERY SERVICING TIPS Page 2 of 3
Recharge the batteries immediately after discharge by constant current charging at 6% of the rated Ah capacity of the battery upto 2.75 VPC, till
the batteries are fully charged- i.e. All cells are gassing freely, constant voltage, constant sp. Gr., theoretical 130% Ah input given, when 100% of
Ah taken out during discharged.
Adjustment of Sp. Gravity Procedure:
After batteries are fully charged, the sp. Gravity of the electrolyte of all cells to be adjusted to the service gravity i.e. 1.210 /1.250 ± 0.005, at
27ºc. the batteries to be put on charge for proper mixing.
If sp. Gravity in cells more than service gravity corrected to 27ºc. Take out acid and add battery grade water, when on charge for proper
mixing.adjust sp. Gravity to the service gravity corrected to 270 c. As applicable with respective batteries.
If the sp. Gravity of the cells less than the service gravity at 270 c take out acid and add 1.400 sp. Gr. Acid by few drops, on charge for proper
mixing. Adjust the sp. Gravity to the service gravity at 270 c as applicable.
After adjustment of the specific gravity, continue the charging for 1- 2 hours for proper mixing of the electrolyte. Stop the charging and allow
the batteries to cool, before commissioning.
The normal failure modes of lead - acid batteries
Sulphation in cells
Over discharge
Allowing a battery to stand idle
Starvation
Allowing electrolyte to fall below the top of plates
Impurities
Adding acid instead of water
Bucking of plates:
Over discharge
Continued operation with battery in starved condition
Charging at high rates
Non- uniform distribution of current over the plates, due to repeated deep discharge
Shedding of active materials:
Normal shedding
Excessive charging rate, or overcharging
Charging sulphated plates at too high rate
Charging only a part of the plate
Deep discharge battery on normal charge.
Freezing.
Container trouble:
Rough handling: any storage battery to be handled as if made of glass, though the containers made with hard rubber, SAN or FRP. Heavy
batteries should be handled by more than one person or by mechanical handling and not to be dropped / dragged. This will lead container
crack/ damage.
Explosion in cell: may cause due to open flame, electrical sparks and clogged vent holes.
Bulging of container: this is be due to under curing of the container.
Stacking should be restricted to max. 3 high, with hard board in between layers
Terminals/ connector corrosion:
Too much topping water added to cells
Battery poorly sealed
Loose vent caps / float guide
Electrolyte spillage
Battery cable damaged, or loose
Connecting bare wires directly to battery terminals.
Loose terminal connections
Non application or renewal of petroleum jelly for protection
Loss of capacity:
Impurities in the electrolyte
sulphation
Loose active materials
Incorrect proportions of acid and water in the electrolyte
Separators clogged
Shedding
Low level of electrolyte
Effect of age
Internal short circuit:
Worn out separators
Lead run
Foreign material
Accumulation of sediment
Reversal of plates:
Assembling of the cell in reverse direction.
Charging a battery in wrong direction.
Lagging / defective cell in battery bank will be reversed if not taken care in time
Earth / surface leakage in battery:
Over filling of battery water.
Careless hydrometer use, spillage of electrolyte.
Careless acid filling during initial filling & charging.
Electrolyte problem:
High sp. Gravity of electrolyte
Low sp. Gravity of electrolyte
High level of electrolyte
Low level electrolyte
Impurities
The importance of 'equalising charge'
To ensure that every cell in a battery bank is maintained in healthy state to give enhanced life & performance it is advisable to give ‘equalising
charge’ atleast once in a year. Under ‘constant potential’ mode during operation a passive layers form on the plates. This causes variation of
sp.gravity & voltage from cell to cell. To take care the battery bank to be put on ‘constant current charging at 6% of rated capacity upto 2.75VPC,
followed by an extended charge for 12 to 24 hours on ‘constant current’ charging at 3% of rated capacity. By this the cells are rejuvinated with
fresh layer of active material, all the cells will show approx. Same sp. Gravity & voltage. As low current was given during 3% rated amps of the Ah
capacity. This will not affect the activated portion of the plates, but will remove the patches of sulphate from the plates back to the solution,
increasing the sp. Gravity of cells. so, it is mandatory to give equalising charge, once in ayear,if not earlier.
http://www.exide4u.com/exide/JSP/masters/Batteryservicing/ser_tips.htm 8/28/2012
.: EXIDE :. BATTERY SERVICING TIPS Page 3 of 3
Hose clamps Filter cartridge Flow indicator PVC hoses Dust cap Connectors
Autofil system
Exide offers a complete system for automatic water filling ( topping-up ) of lead acid batteries for railways, electric forklift trucks, 2v / monoblock
tubular batteries & plante’ type batteries.
Topping up of large number of cells manually is difficult and time consuming. It also causes spillage of water and acid and spoils environment.
Exide autofil system is an intelligent and efficient alternative where replenishment of water is done automatically without manual intervention.
Exide supplies the total system including necessary storage tank, pipelines, autofil plugs and all peripherals. Installation is also carried out on
request.
A float operated watering plug. All parts are manufactured in acid proof plastic material.
Hoses in transparent PVC.
All the necessary connectors and peripheral parts.
Filters, flow indicators and quick connect couplings the water enters the cell through the ‘autofil plug’ and raises the electrolyte to a preset level
controlled by the float. The float raises and closes the valve in the plug by a 2.5:1 level action. when the electrolyte level drops the float operated
valve will open automatically.
http://www.exide4u.com/exide/JSP/masters/Batteryservicing/ser_tips.htm 8/28/2012