INSTRUCTIONS FOR INSTALLATION AND FIRST CHARGE

OF

PLANTE (N/A) BATTERIES

USED WITH

FLOATING AND TRICKLE CHARGE SYSTEM

1.

UNPACKING

The recommended shelf life of dry & uncharged Exide Standby cells is two (2) years from the date of manufacture. 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 quantitywise and qualitywise before erection rather than going for unpacking and erection cell by cell. Proper care is to be exercised for handling the cells. While lifting the cells , please ensure that no hooks are passed through the terminal bolt as it may displace the elements inside. All the items should be carefully checked against the accompanying advice notes/challans and shortages/ damages (if any ) noted for obtaining replacements/spares from the company in time i.e. 30 days from the date of receipt of materials at site. 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. 2. BATTERY ROOM

Battery rooms must have sufficient ventilation to disperse the gasses produced when the batteries are on charge. Exhaust fans should be provided in the rooms. The floor and walls of the battery room should preferably have acid resistant coating. Where batteries are installed in cubicles, sufficient clearance should be allowed between the cells and cubicle walls to prevent any short circuit. Warning signs should be put on the walls indicating dangers of explosion in using naked flames for smoking inside the battery room. The layout of the cells should be such that the end polarities of the battery are physically separated from each other to prevent accidental shorting of these terminals. 3. STAND / STILLAGE

Suitable stands/stillages should be provided for the support of the cells and should be arranged so that each cell will be easily accessible for inspection, topping up etc. When special drawings have been made available showing the layout of the battery , they should be followed very carefully to ensure that connections fit properly. 4 INSTALLATION OF THE CELLS

The following should be kept in mind while finalising the battery layout: 1. Easy access to the individual cells of the battery 2. Locating the take-offs for easy connection to the charging equipment/load. 3. 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. 4. 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 . 5. 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 .

5.

FASTENERS ( BOLT & NUTS)

Before connecting up , apply an even coating of petroleum jelly to the bolts, nuts, washers, connectors and terminal pillars. Cover the whole length of each terminal pillar with petroleum jelly and tighten the bolt connectors firmly using two spanners, one on the bolt head and one on the nut. Note particularly that the positive terminal of one cell is connected to negative terminal of the next throughout the battery , leaving the positive and negative terminals of the battery 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. 6. 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. 7. ELECTROLYTE

Battery grade Sulfuric Acid conforming to IS:266-1993 diluted with distilled water to Specific Gravity 1.190 0.005 at 27Deg C required for filling the cells. This is normally supplied with the battery. If the acid is obtained in concentrated form, it is necessary to dilute it to 1.190 sp. gr. The acid as well as the distilled water to be used for diluting the acid should conform to IS 266-1993 & IS1069-1993 respectively. Suitable vessel for mixing the acid and water is lead-lined wooden boxes. Due to considerable heat evolved during this process, glass or plastic containers must not be used, although jugs made of these materials are ideal for handling dilute acid. WHEN MIXING ACID , OBSERVE THE FOLLOWING PRECATIONS METICULOUSLY: Put the water in mixing vessel first, then add the acid slowly and cautiously, stirring continuously and adding only a little at a time . Never add water to the strong acid. Since it will splash dangerously. Allow the mixture to cool to room temperature before pouring it into the cells. 8. INITIAL FILLING OF CELLS

Sufficient quantity of battery-grade sulphuric acid and a little to spare must be available at the site for the initial filling of the cells. The sulphuric acid should be 1.190 0.005 Sp. Gr. ( at 27Deg C) 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. Used porcelain, glass or plastic jug for filling the cells. Metallic vessels must not be used. Fill the cells to the MAX level line on the transparent container / mark of float indicator (for opaque container ) and leave to allow the acid to soak into the separators and plates for a period of 6 12 hours. The plates will absorb the electrolyte and the electrolyte level will drop. Restore the electrolyte level at the end of this 6 - 12 hours period by adding more acid of 1.190 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. Initial charging must commence with in 24 hours of electrolyte filling & it is therefore essential to ensure that the charge is in proper working condition prior to electrolyte filling of the cells. 9. FIRST CHARGE

Charging should be started after the electrolyte is allowed to cool down from the heat generated during initial filling but not later than 24 hours after filling the first cell with acid, ensuring that the level of electrolyte is adjusted correctly to the MAX position. The charge can be started at any convenient current between the starting rate and finishing rate as specified for the particular cell type. The current should however, be reduced to the finishing rate as soon as the voltage of the battery on charge reaches 2.36 volts per cell and the cells begin to gas. The charge should preferably be given continuously but where this is not possible, it should be ensured that the interval between disruption /restart do not exceed 8 10 hours. The starting rate , the finishing rate and the total minimum AH input should be as per data furnished. During charging cells may need to be topped up with electrolyte of 1.190 sp.gr. if the electrolyte specific gravity is below 1.200 . If above , topping up during charging is to be done with distilled water. 10. READINGS DURING FIRST CHARGE

At the end of each hour, record the battery voltage and the charging current ensuring that the charging current is manually controlled to the specified value. At the beginning of initial charge, readings for specific gravity at intervals of four (4) hours with corresponding readings for the electrolyte temperature are to be recorded for all cells. Once 80% of total minimum AH input is given it is advisable to take hourly readings of voltage and specific gravity corrected to 27 Deg C employing the correction factor till completion of initial / first charge. Pilot Cells: For easy monitoring it is recommended to select Pilot Cells one out of every 60 cells or part thereof (except end cells) for recording hourly voltage , sp. gr. & temperature readings. 11. COMPLETION OF CHARGE

First charge at finishing rate should be continued until all the signs of completion of charge are observed , as undera). 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 remain constant. The charge should be continued until the specific gravities have attained constant figures 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 figure. The exact figure is not so important as long as a Voltage around 2.65 Volts is attained. Typical figures range from 2.65 2.75 Volts per cell at the finishing rate of charge , depending on the prevailing electrolyte temperature , which, when higher than 27 Deg C, tends to depress the voltage slightly from the ideal top of charge of 2.75V at 27 Deg C. 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 fail to gas or is late in gassing or if it 's gravity is lower than those 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) Color of plates : The positive plates should assume a full rich chocolate colour and negatives a smooth light grey when fully charged. This is applicable in transparent containers. When all these signs of completion of charge have been observed, the charge should be terminated. About one hour afterwards, when the gas bubbles have cleared away, the specific gravity and temperature should be recorded. 12. ADJUSTMENTS OF SPECIFIC GRAVITIES

With the electrolyte at the Max level, the correct fully charged gravity is 1.200 at 27 Deg C . if any cell is outside the tolerance of 0.005 i..e. below 1.195, or above 1.205 it should be suitably adjusted. In case of high sp. gr., remove a little of the electrolyte with the aid of the syringe type hydrometer and makeup to the acid level by adding distilled water. Force the water well down into the cell and have the charging current flowing and the cells gassing to help mix the water with the electrolyte. Repeat the process until specific gravities are within specified range. In case of low sp. gr., remove a little electrolyte and add stronger acid ( say Sp. Gr. 1.400) a few drops at a time and with the cells on charge and gassing ass described above. Repeat the process until specific gravities are within the stipulated range. Never make an adjustment on cell which does not gas on charge 13. ADJUSTMENT OF LEVELS Adjust the level of the electrolye to the MAX acid level position 14. PUTTING INTO SERVICE

If necessary, wipe the cells clean and dry , secure all connections and reapply 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 1.195 to 1.205 at 27 Deg 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 extended service life. At installation where the battery is likely to be on float for prolonged periods without discharge, it is preferable to carry out 3 charge / discharge cycles before putting the battery into service 15. FIRST CHARGE REPORT First charge record sheets are supplied with our batteries. Copy of the same duly filled in, may be forwarded to any one of our Regional / Branch offices for scrutiny and advice.