DURING SPECIFIC GRAVITY

DO's
Hold the hydrometer vertically. Draw electrolyte into the hydrometer a few times. Hold the hydrometer so that the liquid is level in the barrel and at eye level. Read the Specific Gravity at the point on the Calibrated float's scale where the surface of the liquid crosses the float. Check each individual battery cell. Measure the electrolyte temperature with a thermometer for best accuracy. Correcting Hydrometer reading for Temperature: Add 0.007 for every 10oC above 27oC Subtract 0.007 for every 10oc below 27oC

Don'ts

Please note that the Hydrometer readings are likely to be inaccurate in the following instances: Immediately after Adding Water (Never add acid to a battery to raise the electrolyte level, Only add de-mineralized water) While a Battery is being charged (After turning the charge OFF, wait at least 15-20 minutes for the electrolyte to settle.) Following Discharge (Wait at least 15-20 minutes after discharging for the electrolyte to settle)

INSTALLATION OF BATTERY IN THE VEHICLE:

Turn OFF Engine and take out the key. Mark the Positive Cable to remember the proper connection. Remove the Ground / Negative (-) cable first. Use Proper tools to avoid damaging cable clamp bolt heads. Remove the Battery and Clean corrosion/dirt from the Battery Tray and Battery Hold-down Bracket. Ensure that the Battery Tray is free of rocks or other foreign materials. Verify that the Negative / Ground cables Are properly grounded to the frame / Engine block. Place the Battery in the battery tray properly (The Positive post of the automotive batteries is tapered and has a slightly larger diameter). Connect the Positive cable to the positive terminal of the battery first. The "Ground / Negative (-)" cable should be connected to the battery last. Apply Vaseline or Petroleum jelly for the battery terminal posts. Check and Verify for the correct charging voltage (When replacing a battery, always verify that the charging-system voltage is correct before the vehicle leaves the shop).

THE 3-STEP BATTERY CHECK :

STEP1: VISUAL INSPECTION Check Container, Cover and Terminal for damage.

Clean corrosion if present. Check electrolyte level and fill if necessary with De-mineralized water. Check for electrolyte discoloration. STEP2: STATE OF CHARGE Use proper tools to remove vent caps, check with hydrometer. If less than 50 Specific Gravity points difference between highest and lowest cells, proceed to next step.'Or' If more than 50 Specific Gravity points difference and the battery is 75% charged or above, replace battery. Remove surface charge, if battery has been on charge (Charger or Alternator) immediately before testing or if OCV (Open-circuit voltage) is not consistent with specific gravity readings. To remove surface charge, switch on headlights for 30-60 seconds (With Engine off condition). 'Or' Allow battery to sit for 2-3 hours. STEP3: LOAD TEST Apply the CCA rating of the battery for 15 secondsand compare resulting battery voltage (before removing load) to voltage chart. If unable to find CCA rating for battery, refer to manufacturer literature.

HYDROMETER 100% =1.270-1.280 75% =1.230-1.240 Recharge, if one or more Cells are below 1.230 VOLTMETER OC VOLTS=STATE OF CHARGE 12.66 = 100% 12.40 = 75% Recharge if O.C.V. is below 12.40 volts

VOLTAGE CHART DEGREES R 100 900 800 700 600 500 400 300 200 100 C 380 380 270 210 160 100 40 -10 -70 -120

MINIMUM VOLTAGE 9.90V 9.80V 9.70V 9.60V 9.50V 9.40V 9.30V 9.10V 8.90V 8.70V

0 -180

8.50V

USER GUIDELINES:
The top of the battery must be kept clean and dry. Vaseline should be applied to cable clamps and terminals. Never apply grease. Get the fan belt, electrical wiring, alternator and regulator setting checked regularly. The alternator charging voltage setting measured across battery terminals must be maintained at 14.000.20. In case of any drop in electrolyte level, add demineralised water. Never add acid.

CAUTION :
Keep away from sparks, cigarettes and open flame. These can cause explosion. Avoid metallic contact across the terminals, as this can result in short circuit and sparking. It is recommended to return the old battery to the authorized battery manufacturer / dealer / smelter during purchase of a new battery.

Automotive Battery FAQs

How does a battery work? A battery stores energy in chemical form that can be released on demand as electricity. This electrical power is used by the vehicle's ignition system for cranking the engine. The vehicle's battery may also power the lights and other electrical accessories, when needed. In case the alternator/belt fails, the battery might also need to power the vehicle's entire electrical system for a short period of time. How do I know when to replace my automotive battery? If your vehicle has starting problems or needs a push start, there is a possibility that your vehicle battery has a problem (either weak or defective). When my vehicle won't start how do I know for sure if my battery needs to be replaced? Many other problems can keep a vehicle from starting, so you need to do some troubleshooting. Consult with mechanic or auto electrician who will conduct some testing and advise you whether battery need to replace or not? What causes a battery to fail? Heat, vibration, maintenance, ageing and malfunctioning vehicle electrical systems are the largest contributors to battery failures. How can I determine what is the correct battery for my vehicle?Consult your vehicle's owner's manual. It will provide the vehicle manufacturer's group size and CCA rating requirements for your car. Or, ask your battery retailer to refer to his battery application chart for recommended fitment. Remember: Never use a battery with a CCA lower than the manufacturer's recommendation. Also, whenever available, a battery with a higher CCA is more capable of providing for the electrical needs of older vehicles, and will not adversely affect the vehicle's electrical system. What should I consider when buying a battery? SIZE: What are the dimensions of your original battery? POWER: What are the Cold Cranking Amps required to power your vehicle & the AH Capacity at C20 ratings?

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WARRANTY: Automotive batteries are backed by a warranty package. Choose one that is right for your vehicle's needs. What is Cold Cranking Amp (CCA) Rating? This industry rating measures the cranking power a battery has available to start a car's engine at 0 degrees F. Battery Council International defines it as the number of amperes a lead acid battery at 0 degrees F can deliver for 30 seconds and maintain at least 1.2 volts per cell. What MCA or CA rates? This is a rating used to describe the discharge load in amperes which a new, fully charged battery at 32 degrees F (0C), can continuously deliver for 30 seconds and maintain a terminal voltage equal or greater than 1.2 volts per cell. It is sometimes referred to as Marine Cranking Amps or Cranking Amps. What is Reserve Capacity? Reserve Capacity, (RC) is a battery industry rating, defining a battery's ability to power a vehicle with an inoperative alternator or fan belt. The rating is the number of minutes a battery at 80 degrees F (27C)can be discharged at 25 amps and maintain a voltage of 10.5 volts for a 12 volt battery. The higher the reserve rating, the longer your vehicle can operate should your alternator or fan belt fail. Why is battery power not always proportional to its size? A battery's group size is simply a measure of the physical dimensions of the battery. This measure has no relation to the battery's electrical capacity. Regardless of group size (physical dimensions), two batteries are equal in power if the RC and CCA ratings are the same. How does a car's charging system work? A modern automobile's vehicle's charging system consists of 3 major components: Alternator - Mechanical device driven by the engine accessory belt. It provides continuous voltage to replenish the battery while the engine is running. Voltage Regulator - Monitors and regulates the alternator output (voltage), it also increases or cuts-off the voltage according the needs of the vehicle requirement. Battery - An electrical reservoir used to store electrical energy until it is needed by the vehicle's starting system to crank the engine and power the fuel and ignition systems and also to support the accessory loads if the vehicle is not running at adequate speeds.. When I am replacing my battery or cleaning the terminals, why is it important to remove the ground wire first? Before you start, always check the type of grounding system the vehicle has. If you remove the positive connector first in a negative ground system, you risk the chance of creating a spark. That could happen if the metal tool you're using to remove the positive terminal connector comes in contact with any piece of metal on the car. If you are working near the battery when this occurs, it might create an ignition source that could cause the battery to explode. It is extremely important to remove the ground source first. What can excessive heat do to battery? Hot temperatures will deteriorate a battery's life quicker by evaporating the water from the electrolyte, and corroding and weakening the positive grids, and also increases the shedding of active material. What effect does extreme cold have on my battery? Cold temperatures dramatically reduce the effectiveness of chemical reactions within the battery, while increasing the battery's internal resistance. Both of these cause a reduction in cranking power as temperatures drop. Batteries left in a discharged state are also susceptible to freezing, which damages internal components and containers. Cars require an increased amount of cranking power in cold weather, due to the fact that motor oil is thicker and makes engines harder to crank. How should I maintain my automobile battery? Modern automotive batteries need little attention. If your battery has removal vents, checking the water level and adding distilled water as necessary to maintain the level at the bottom of the vent wells will help extend the life of the battery. (Be careful never to overfill, as this will cause acid to be expelled from the vents during normal battery cycling.) Check both terminals regularly for corrosion and tight connections. (If necessary, clean with baking soda and water.) Though all our Batteries are eco-friendly and maintenance-free, a few precautions would further ensure their longevity.

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Use only distilled water for top-ups and do not overfill. Periodically check the voltage regulator output as over and under charging can be harmful to the battery. Batteries may be Zero maintenance but the vehicle auto electrical system requires periodical maintenance/check-ups. In case of maintenance-free (MF, Zero Maintenance with Openable Vent) batteries, vent plugs can be opened with a rupee coin. To protect the batteries from damage, recharge at recommended current (amps) only. Do not keep normal batteries idle for more than 3-4 weeks and MF batteries idle for more than 10-12 weeks. Do not operate or charge battery if electrolyte temperature exceeds 60 o C. When charging, ensure that the current is not more than 1/20 of the rated AH capacity. Put the correct capacity of battery in the vehicle to get the best performance. When placing battery, ensure that it is secured firmly in the cradle. Always keep terminals and clamps clean and grease-free and never hammer down the clamps. Ensure that the clamps are always firmly tightened. Make sure the connecting cables are fixed to the correct poles. (first +ve to +ve then -ve to -ve) Apply petroleum jelly on the terminal cable clamps but never apply grease. How often should I replace my battery? Battery life will vary from vehicle to vehicle based upon many factors. If you experience unsatisfactory performance from the vehicle's starting system, or an instrument panel indication is that there may be a malfunction, take the vehicle to have the electrical/ starting systems checked. Consider an upgrade to a battery with higher cranking performance if you experience insufficient performance from your vehicle's current battery. How do I jump-start a car with a dead battery? Remember: All batteries contain acid and can cause injury if not regarded as dangerous. Wear proper eye and skin protection. Connect the positive cable to the positive terminal of the discharged battery. Connect the other end of the same cable to the positive post on the boosting vehicle's battery. Connect the negative (black) cable to the negative post of the booster battery. Make final jumper cable connection to the engine block of the stalled vehicle. Start disabled vehicle and disconnect cables in reverse order, taking precautions to keep all hands, clothing, hair and cables out of all moving parts. Always loosen the Vent caps of the discharged battery. Terminology Active Material Chemically active compounds in a cell or battery that convert from one composition to another while producing current (electrical energy) or accepting current from an external circuit. Battery Polarity A battery has two poles or posts. The positive battery post is usually marked POS, P, or + and is larger than the negative post which is usually marked NEG, N, or -. The polarity of the charger and the battery must always match to avoid damage to the battery and charger. Cell The basic electrochemical current-producing unit in a battery consisting of a set of positive plates, negative plates, electrolyte, separators and casing. There are six cells in a 12-volt lead-acid battery. Container The polypropylene case which holds the plates, straps and electrolyte. Cover The top lid for the case/container. Electrolyte A solution of sulfuric acid and water which conducts current through the movement of ions (charged particles in the electrolyte solution) between positive and negative plates. It supplies sulfate ions for reaction with the active material of both positive and negative plates. Grids A lead alloy framework that supports the active material of a battery plate and conducts current

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Ground The reference potential of a circuit. In automotive use, the result of attaching one battery cable to the body or frame which is used as a path for completing a circuit in lieu of a direct wire from a component. Today, over 99% of autos use the negative terminal of the battery as the ground Intercell connections Connections between the straps of two cells, positive of one cell to the negative of the next. Open Circuit Voltage (O.C.V.) The voltage of a battery when it is not delivering or receiving power. It is 2.11 volts for a fully charged battery cell. Plates Flat, typically rectangular components that contain the active material and a mechanical support structure called a grid, which also has an electrical function, carrying electrons to and from the active material. Plates are either positive or negative, depending on the active material they hold. Separators Porous plastic, electrically insulating sheets which allow transfer of ions between plates, but prevent physical contact between plates and resulting electronic conduction State of Charge Use this chart to determine the State of Charge for a Deep Cycle Battery at 20 degrees to 27 degrees Celsius

State of Charge 100% 75% 50% 25%

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Specific Gravity 1.265 1.225 1.19 1.155

Voltage - 12 Volt Battery 12.7 12.4 12.2 12.1

Straps Lead alloy castings that connect a number of same polarity plates together in a cell and carry current Terminals The electrical connection from the battery to the external circuit. Each terminal is connected to either the first (positive) or last strap (negative) in the series connection of cells in a battery. BIC Vents Components that allow gasses cool down and get condensed, and excess gases to exit the battery while retaining the electrolyte within the case. Can be permanently fixed to the cover or removable, depending on battery design Recycling a Battery Disposal of batteries is an environmental concern. Hence we should adhere to disposal procedure. Do not dispose batteries in trash. Take the batteries to the place of purchase for disposal. Battery outlets will accept the batteries that you bring for disposal. Battery acid is recycled by neutralizing it into water or converting it to sodium sulfate for laundry detergent, glass and textile manufacturing. Plastic is recycled by cleaning the battery case, melting the plastic and reforming it into uniform pellets. Lead, which makes up 50% of every battery, is melted, poured into slabs and purified.