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CAMTECH/E/2003/VRLA/1.

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CAMTECH/E/2003/VRLA/
CHAPTER 3

TROUBLE SHOOTING
CAUSES, EFFECTS AND REMEDIES
Trouble Cause Effect Prevention
Over  Continuous charging of batteries at a  Excessive gassing The corrective action for this is
Charging higher voltage (i.e. more than resulting in loss of  Adjust the float voltage to
specified value) can cause water. 2.25 VPC at 20% (max.)
overcharging of batteries.  Dry out of current limit of the rated
 The higher voltage can be due to either separator capacity.
the set point in charger itself is high or  Increases the  Connect the
connecting less than temperature of the cell. required number of cells.
required number of cells (or) some  This over  Isolate the battery bank
cells in the bank charging causes from heat sources.
are removed/by-passed (or) due to corrosion of positive
calibration error in the measuring plates.
instrument.

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Maintenance Handbook on VRLA Batteries for TL/AC Coaches Oct.,2003
CAMTECH/E/2003/VRLA/1.0

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CAMTECH/E/2003/VRLA/
Trouble Cause Effect Prevention
Under  Continuous charging of batteries at a  Consistent under charging of When this
charging lower voltage (i.e. less than specified the battery results in a occurs, charge the
value) can cause under charging of gradual running down cells at 2.25 volts until
batteries. of the cells. all the cells reaches to
 The loose terminal bolt connections can  In-sufficient charging causes normal condition.
also cause under charge. buckling of plates. Since the
 Setting voltage is low in the charger or lead sulphate occupies more
calibration error in the measuring space than the original
instrument. material.

Difficulties  Malfunctioning of It causes over charging or under Once in three months,


with charging Charger/Rectifier. charging. these protections have
system  Failure of any component used in to be checked.
Charger/rectifier.
 Sudden failure of charging voltage
controlling circuit.
 Under voltage, over voltage protections
are not provided.

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 Higher ripple content.
Maintenance Handbook on VRLA Batteries for TL/AC Coaches Oct.,2003
CAMTECH/E/2003/VRLA/1.0

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CAMTECH/E/2003/VRLA/
Trouble Cause Effect Prevention
Corroded  Sulphation formed on the terminal posts.  Corroded terminals may prevent a Remove the
Terminals  Terminal posts not cleaned battery from delivering connectors and clean the
properly. sufficient current. terminals with
 Batteries stored in open place.  Voltage drops suddenly during brass brush. After giving
discharge connection, apply a thin film
of petroleum jelly.
Cracked/  Cracks on cover, jar or heat- seal area.  A slight crack on cover will Cells having this defect
broken jars  Damaged during transit. effect the recombination should be replaced.
and  Damaged during unloading. efficiency & results in
covers  Damage caused due to diminishing the
mishandling. capacity of the cell.
 Cracks at heat seal will result in
the gradual discharge of cells.
 Cell will become dry.

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Maintenance Handbook on VRLA Batteries for TL/AC Coaches Oct.,2003
CAMTECH/E/2003/VRLA/1.0

1.0
CAMTECH/E/2003/VRLA/
Trouble Cause Effect Prevention
Sulphation  Both positive and negative Gradually capacity of the Battery may be put on
plates got sulphated (i.e. forming of Pb cell will be running down. Sudden charge at low rate of current i.e.
SO4) drop in voltage will be observed. 3% of the rated cell capacity till
 Keeping the battery in discharged the cell voltage reaches
2.15 to 2.20 V.
condition for a long time.
 Continuous undercharging.
Grid  Oxidation of positive grid Long continued over- Adjust the charging
corrosion structure. charging cause oxidation of the voltage as per
 Continued higher setting of positive grid structure, decreasing specification.
charging voltage in the cross section of grid wires and
eventually leading to collapse of
chargers/rectifiers.
the plate.

Cell  Showing negative voltage Total voltage suddenly Battery may be put on
reversal when measured across drops. charge at a low rate of current
terminals of a cell. i.e. 3% of the rated cell capacity
 Reversal may be caused by the over till the cell voltage reaches
2.15 to 2.20 V.
discharge of a cell.
 Terminal bolts not properly

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tightened.
Maintenance Handbook on VRLA Batteries for TL/AC Coaches Oct.,2003

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