INSTALLATION&

OPERATINGINSTRUCTIONS

SECTION 93.10 2010-03INDUSTRIAL ENERGY

TECHNOLOGIES

YOUR EXIDE REPRESENTATIVE

SALESPERSON

TELEPHONE

LOCATION

EXIDE SERVICE ASSISTANCE1-800-241-4895

Page

SECTION 11.0 General Information . . . . . . . . . . . . . . . . . . . .1

SECTION 22.0 Safety Precautions . . . . . . . . . . . . . . . . . . . . .1

SECTION 33.0 Receipt of Shipment . . . . . . . . . . . . . . . . . . .13.1 Concealed Damage . . . . . . . . . . . . . . . . . . . .23.2 Electrolyte Levels . . . . . . . . . . . . . . . . . . . . . .2

SECTION 44.0 Storage Prior to Installation . . . . . . . . . . . . . .24.1 Storage Location . . . . . . . . . . . . . . . . . . . . . .24.2 Parts and Accessories . . . . . . . . . . . . . . . . . .24.3 Storage Interval . . . . . . . . . . . . . . . . . . . . . . .24.4 Dry Charged Batteries . . . . . . . . . . . . . . . . . .2

SECTION 55.0 Rack Assembly . . . . . . . . . . . . . . . . . . . . . . .2

SECTION 66.0 Unpacking and Handling . . . . . . . . . . . . . . . .2

SECTION 77.0 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .37.1 Battery Location . . . . . . . . . . . . . . . . . . . . . . .37.2 Temperature . . . . . . . . . . . . . . . . . . . . . . . . . .37.3 Temperature Variation . . . . . . . . . . . . . . . . . .37.4 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . .37.5 Placement of Cells . . . . . . . . . . . . . . . . . . . . .37.6 Connecting Cells . . . . . . . . . . . . . . . . . . . . . .47.7 Completing Installation . . . . . . . . . . . . . . . . .6

SECTION 88.0 Initial Charge . . . . . . . . . . . . . . . . . . . . . . . . .78.1 Constant Voltage Method . . . . . . . . . . . . . . .78.2 Initial Charge-Electrolyte Levels . . . . . . . . . .7

SECTION 99.0 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .79.1 Floating Charge Method . . . . . . . . . . . . . . . .79.2 Float Charge-Float Voltages . . . . . . . . . . . . .79.3 Voltmeter Calibration . . . . . . . . . . . . . . . . . . .89.4 Cycle Method of Operation . . . . . . . . . . . . . .89.5 Recharge . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

SECTION 1010.0 Equalizing Charge . . . . . . . . . . . . . . . . . . . . .810.1 Equalizing Frequency . . . . . . . . . . . . . . . . . .810.2 Equalizing Charge Method . . . . . . . . . . . . . .910.3 Equalizing Individual Cells . . . . . . . . . . . . . . .910.4 Equalizing Charge—Electrolyte Levels . . . . .9

SECTION 1111.0 Specific Gravity . . . . . . . . . . . . . . . . . . . . . . .911.1 Hydrometer Readings . . . . . . . . . . . . . . . . .1011.2 Correction for Temperature . . . . . . . . . . . . .1011.3 Correction for Electrolyte Level . . . . . . . . . .1011.4 Specific Gravity Range . . . . . . . . . . . . . . . .10

INDEXPage

SECTION 1212.0 Cell Voltage Variation . . . . . . . . . . . . . . . . . .1012.2 Cell Voltage Variation–Damp Covers . . . . . .1112.2 Cell Voltage–Temperature Correction . . . . .1112.3 Correction Factor . . . . . . . . . . . . . . . . . . . . .11

SECTION 1313.0 Pilot Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

SECTION 1414.0 Records . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

SECTION 1515.0 Water Additions . . . . . . . . . . . . . . . . . . . . . .1215.1 Water Purity . . . . . . . . . . . . . . . . . . . . . . . . .12

SECTION 1616.0 Tap Connections . . . . . . . . . . . . . . . . . . . . .12

SECTION 1717.0 Temporary Nonuse . . . . . . . . . . . . . . . . . . .12

SECTION 1818.0 Battery Cleaning . . . . . . . . . . . . . . . . . . . . .1218.1 Styrene Acrylonitrile Containers with

Butadiene Styrene Covers . . . . . . . . . . . . . .1218.2 Polycarbonate Containers and Covers . . . .12

SECTION 1919.0 Connections . . . . . . . . . . . . . . . . . . . . . . . . .1319.1 Connection Resistance . . . . . . . . . . . . . . . .1319.2 Retorquing Connections . . . . . . . . . . . . . . .1319.3 Connection Resistance Measurement . . . . .14

TABLESTABLE A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7TABLE B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7TABLE C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8TABLE D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9TABLE E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9STATIONARY BATTERY MAINTENANCEREPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

FIGURESFIGURE 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2FIGURE 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4FIGURE 2A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5FIGURE 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6FIGURE 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6FIGURE 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10FIGURE 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14FIGURE 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14FIGURE 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14FIGURE 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14FIGURE 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

SECTION 1

1.0 General Information

Caution! Before proceeding with the unpacking, handling,installation and operation of this lead-acid storage battery,the following general information should be reviewed togeth-er with the recommended safety precautions.

A lead-acid battery is an electro-chemical device containingelectrolyte which is a dilute solution of sulfuric acid andwater. This electrolyte is corrosive and can cause injury.

Lead-acid batteries, when installed, are capable of high volt-age which can cause electrical shocks to personnel.

All lead-acid batteries, in the course of normal operation,generate gases which could be explosive.

Stationary batteries (when installed) are usually on floatcharge continually, unless on discharge in the event of ACfailure, or on recharge following a discharge.

SECTION 2BATTERY WARNING STATEMENT

DANGER

2.0 Safety Precautions

A. Wear rubber apron, gloves and safety goggles (or faceshield) when handling, installing, or working with batter-ies. This will help prevent injury due to splashing orspillage of sulfuric acid.

B. Prohibit smoking. Keep flames and sparks of all kinds awayfrom vicinity of storage batteries as liberated or entrappedhydrogen gas in the cells may be exploded,causing injury topersonnel and damage to cells.

C. Never place metal tools on top of cells, since sparks due toshorting across cell terminals may result in an explosion ofhydrogen gas in or near the cells. Insulate tool handles toprotect against shorting.

D. When preparing electrolyte, always pour acid into water,NEVER water into acid. Failure to follow this precautionwill result in excess heat and violent chemical reactionwhich may cause serious injury to personnel.

E. If electrolyte comes into contact with skin or clothing,immediately wash with water and neutralize with a solu-tion of baking soda and water. Secure medical treat-ment. If electrolyte comes into contact with the eyes,wash or flush with plenty of clean water. Secure medicaltreatment immediately.

F. Exercise care when handling cells. When lifting strapsand strap spreaders are provided, use them with appro-priate mechanical equipment to safely handle cells andavoid injury to personnel.

G. Promptly neutralize and remove any electrolyte spilledwhen handling or installing cells. Use a baking soda/watersolution (1 lb. per gallon of water) to prevent possibleinjury to personnel.

H. Make sure that all battery connections are properly pre-pared and tightened to prevent possible injury to per-sonnel or failure of system.

I. Familiarize personnel with battery installation, chargingand maintenance procedures. Restrict access to batteryarea, permitting trained personnel only, to reduce thepossibility of injury.

J. Whenever possible, when making repairs to chargingequipment and/or batteries, interrupt AC and DC circuitsto reduce the possibility of injury to personnel and dam-age to system equipment. This is particularly importantwith high voltage systems (110 volts and above).

K. When maintaining a connected battery string, caremust be taken to prevent a build-up of static charge.This danger is particularly significant when the worker iselectrically isolated, ie. working on a rubber mat or anepoxy painted floor or wearing rubber shoes. Prior tomaking contact with the cell, discharge static elec-tricity by touching a grounded surface. Wearing aground strap while working on a connected battery stringis not recommended.

NOTE: If the foregoing precautions are not fully understood,clarification should be obtained from your nearest Exide rep-resentative. Local conditions may introduce situations notcovered by Exide Safety Precautions. Here again, contactthe nearest Exide representative for guidance with your par-ticular safety problem; also refer to applicable federal, state,and local regulations as well as industry standards.

SECTION 3

3.0 Receipt of Shipment

Immediately upon delivery by the carrier, examine for possi-ble damage caused in transit. Damaged packing material orstaining from leaking electrolyte would indicate rough handling.

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HIGH VOLTAGEHigh voltages are present on most battery systems.Exercise caution and REMOVE ALL METALOBJECTS FROM PERSON when working on oraround battery.

EXPLOSIVE GASESGases produced by battery can be explosive.DONOTSMOKE, USE AN OPEN FLAME, CREATE AN ARCor SPARKS IN VICINITY OF BATTERY. WEAR EYEPROTECTION.Personnel should discharge staticcharges from their person to ground before working onbattery. Ventilate well in an enclosed space and whencharging.

ACID BURNSBattery contains SULFURIC ACID WHICH CANCAUSE SEVERE BURNS. Avoid getting in eyes, onskin, or on clothing. In case of contact, flush immediate-ly and thoroughly with clean water. OBTAIN MEDICALATTENTION.

If such conditions are found, make description notation ondelivery receipt before signing. If cell damage is found,request an inspection by the carrier and file a damage claim.Also notify local Exide representative of action taken.

3.1 Concealed Damage

Shortly after receipt (within 15 days), examine all cells forconcealed damage. Pay particular attention to packingmaterial exhibiting damage or electrolyte staining. Performexamination prior to installation and disposal of packingmaterials. Cells with electrolyte levels more that 1/2" belowtop of plates have suffered probable permanent damagedue to plate exposure to air. If this condition or other celldamage is found, request an inspection by the carrier imme-diately and file a concealed damage claim. Examine cellsfor container damage, misaligned elements, broken plates,or any other visible damage.

3.2 Electrolyte LevelsCells are shipped with electrolyte levels about 1/8" below thehigh level line. During shipment, the levels drop due to theloss of gases from internal cell components. The amount ofdrop in level will vary with each type of cell. Electrolyte lev-els, when received, may range from the high level line toslightly below the low level line. If this condition exists, makeno addition of electrolyte or water at this time (see Section8.2). If certain cells have low electrolyte levels, with lessthan 1/2" of plates exposed to air, add battery grade sul-phuric acid of the same specific gravity as the remainingcells; thus bringing low level cells up to the average level ofother cells.

SECTION 44.0 Storage Prior to Installation

4.1 Storage LocationIf the battery is not to be installed at the time of the receipt,it is recommended that it be stored indoors in a cool, 60° F(15.6° C) to 90° F (32° C), clean, dry location. Do not topload pallets or possible cell damage may occur.

4.2 Parts and AccessoriesPrior to planned installation of battery, the separately pack-aged parts and accessories should be opened and checkedagainst shipping invoice for completeness. Discovery ofmissing or incorrect parts during installation may causedelays resulting from reordering and shipment of replace-ments. Store parts in safe location to prevent loss.

4.3 Storage IntervalFor batteries shipped wet, fully-charged, the following stor-age intervals from date of shipment to date of installationand initial charge should not be exceeded:

Lead-Antimony Types:Three (3) Months

Lead Calcium Types:Six (6) Months

Storage beyond the above stated periods can result in sul-phated plates which can be detrimental to battery life andperformance.

The battery should be given its initial charge (see Section8.0) before the end of the above stated storage intervals andrepeated for each additional storage interval.

If permanent installation is deferred for an extended timeperiod, the battery may be temporarily connected and main-tained on a floating charge (see Section 9).

Failure to charge in accordance with the above can void thebattery's warranty.

4.4 Dry-Charged BatteriesFor batteries shipped dry-charged, follow special handlingand preparation instructions supplied as well as appropriatesections of this Manual.

SECTION 5

5.0 Rack AssemblyAssembly of the battery rack should be completed in accor-dance with the Exide drawing and/or instructions includedwith the rack.

SECTION 6

6.0 Unpacking and HandlingMost cells are packed in individual corrugated cartons.Some smaller size cells are packed in a master carton con-taining 2 (two) or 3 (three) cells. Cartons are shipped onwood pallets.

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Figure 1

Remove material holding cartons to pallets, exercising carewhen cutting banding material to prevent injury. If individualcells are to be moved to another location, do not remove car-ton at this time. Exercise caution if using a two-wheeledhand truck and, to prevent spillage of electrolyte, do not tiltcell more than 25 degrees from vertical. When cells havebeen brought to the installation sight, remove carton sleeveand top corrugated spacers.

DO NOT LIFT CELLS BY THEIR TERMINAL POSTS.Support the cells from the bottom when handling andunpacking. In general, units weighing less than 75 poundsare handled manually, being supported from the bottom.

After removal of outer carton and top spacers, the cell should stillbe resting in the bottom corrugated tray. This tray is designed tobe easily broken away to permit positioning of a lifting strapunder the cell with a minimal amount of cell tilting.

A lifting strap and a strap spreader are furnished for use withmechanical lifting devices, when cells weigh 75 pounds ormore. See Figure 1 which shows typical positioning of strapand spreader. Large cells are provided with 2 lifting strapsand a special spreader for stability in handling during instal-lation.

Always use lifting straps and spreaders, when provided,together with suitable mechanical lifting devices to preventinjury to personnel or damage to cells.

Platform lifts of adequate capacity to handle cell weights anddimensions may be used provided they are stable and capa-ble of reaching needed heights and used on smooth andlevel floor conditions.

Never slide cells across rough surfaces as severe scratchingof plastic container bottom may result in stressing and rup-turing of the jar with subsequent loss of electrolyte. At alltimes, exercise care when handling cells to prevent scratch-ing of plastic jars and covers.

SECTION 77.0 Installation

7.1 Battery Location

It is recommended that the battery be installed in a clean,cool, dry location. Cells should not be exposed to heatingunits, strip heaters, radiators, steam pipes or sunshinethrough a window. Any of these conditions can cause a seri-ous electrolyte temperature variation among cells within abattery (see Section 7.3).

7.2 Temperature

A battery location having an ambient temperature of 75°F(24°C) to 77°F (25°C) will result in optimum battery life.Batteries operated in high ambient temperatures will resultin reduced life. Therefore, for longer life and ease of mainte-nance, locations having cooler ambient temperatures arerecommended. The normal battery operating temperaturesare between 60°F (16°C) and 90°F (32°C).

7.3 Temperature Variation

The location of rack arrangement should result in no greaterthan 5°F (2.78°C) variation in cell temperatures in a seriesstring at any given time. If a greater variation is found, stepsshould be taken to correct the condition. When uniform celltemperature is maintained, the need for equalizing chargesmay be eliminated or reduced in frequency.

7.4 Ventilation

In the operation of lead-acid battery whether it be on initialcharge, float charge, equalizing charge or recharge followinga discharge, hydrogen and oxygen gases are produced.This results from electrolysis of the water portion of the elec-trolyte by the charging current.

Ventilation should be provided in the battery room or area toprevent hydrogen, liberated from the cells in service, fromexceeding a 1% concentration. Concentrations above thispercentage can result in an explosive mixture, which couldbe ignited by sparks from adjacent electrical equipment aswell as accidental sparks or open flames introduced by per-sonnel. All air moved by ventilation in the battery room orarea should be exhausted into the outside atmosphere andshould not be allowed to recirculate into other confinedareas.

7.5 Placement of Cells

It is assumed at this point that the battery rack has beenassembled. Study the rack layout and wiring drawings todetermine proper location of the positive and negative ter-minals of the battery; this will establish correct positioning ofthe initial cell on each rack row. Cells are normally installedwith plate edges perpendicular to rack length.

Measure and mark the center of the rack stringer length.Determine the number of cells to be placed in each row.When an odd number of cells are in the row, place the cen-ter of the initial cell at the center point of the rack stringerlength.

When an even number of cells are in the row, locate the ini-tial cells so that the center of the space between the cellscoincides with the center mark of the stringer length.

To minimize friction of cells when transferring from platformlift to the rack rails or for positioning of cells, talcum powdermay be used on the platform surface or plastic rack strips toease movement.

CAUTION!DO NOT USE ANY OTHER TYPE OFLUBRICANT SUCH AS GREASE OR OIL ASTHEY MAY CONTAIN MINERAL SPIRITSWHICH CAUSE CRAZING AND CRACKINGOF THE PLASTIC JAR MATERIAL.

DO NOT USE METAL RODS, SCREW-DRIVERS, ETC. THROUGH POST HOLESTO LATERALLY MOVE CELLS AS CELLSHORTING AS WELL AS DAMAGE TO THEPOST SEALS COULD OCCUR.

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When installing cells on the rack, start at the lower step ortier for stability and safety reasons.

Place cells on the rack so that the positive terminal (marked“+”) of each cell adjoins the negative terminal (marked “-”) ofthe next cell. The standard spacing between cells is 1/2” atthe top of the jars.

Adjacent cells should not touch; nor should any cell contactthe metal rack supports or metal cable conduits. Check forproper alignment and 1/2” spacing between cells. Adjustcell position where necessary. This should be completedbefore installation of intercell connectors.

Use two 1/2” thick pieces of plywood cut to cell width and 1”higher than jar height to expedite positioning of cells. Spacecells by placing one piece between the first cell positionedand the next cell. In positioning the third cell, use the sec-ond piece of plywood for spacing. The first piece is removedand used for the next cell placement, etc.

The cell post surfaces have a coating of NO-OX-ID greaseor approved equal applied at the factory. Do not remove anygrease from posts. Re-coat any surfaces that may havebeen exposed during handling of cells.

Also closely examine factory coated post contact surfacesfor presence of foreign substances which may have beenintroduced through handling or construction activity in theinstallation area. If the foregoing is noted, remove the NO-OX-ID grease or approved equal with paper wipers andapply a new coating. Also inspect posts for corrosion. If cor-rosion is found, clean posts with brass suede brush or plas-tic scouring pad and re-grease.

7.6 Connecting CellsRefer to the cell arrangement drawing to determine thequantity, size, and correct positioning of the intercell con-nectors. On the “N” type cells using 1 1/4” wide connectors,the bolt holes are located off-center. Position the connectorso that the lesser dimension faces downward on the cellpost.

Gently clean contact surfaces only of the lead plated inter-cell connectors, terminal plates and cable lugs using a brasssuede brush or 3M Scotch Brite scouring pad. Caution: Donot use powered wire brush or course abrasives, as leadplating may be removed exposing copper.

As contact surfaces of posts and connectors are cleaned,apply a thin coating of NO-OX-ID grease or approved equalto these surfaces only.

Starting at center of the cell row, install connectors perwiring diagram and cell arrangement drawing furnished withthe battery.

On cells using stainless steel bolts, washers and nuts, makesure a washer is placed between the bolt head and connec-tor as well as between the nut and connector with the rollededge against the connector. Never install washers betweenthe connector and the cell post. (See figure 2A).

As intercell connectors are installed, adjust them to a levelposition and finger tighten hardware.

After all connectors are installed, the hardware should betightened using insulated tools as outlined in the followingillustration. (Figure 2):

Figure 2

Torque both the bolt head and the nut of stainless steelhardware to their prescribed torque values. Torquing onlyone side of either combination will not provide the desiredtightness.

Re-torque stainless steel hardware 4 to 6 hours after initialtorquing to allow for initial relaxation of connection compo-nents.

Complete connecting of cells by installing necessary inter-row, inter-tier or inter-rack cable connectors. Do not connectbattery to charger at this time.

Take and record connection resistances (See Section 19.0)of cell to cell and cell to terminal (including inter level andload connections). This is particularly important on high rateapplications. Remake any connection that has a value morethan 10% or 5 u Ω, whichever is greater.

Re-check to be certain that the cells are connected positive(+) to negative (-) throughout the battery string. Measurethe total voltage at the battery terminals. The voltage shouldbe equal to the number of cells times the voltage of one ofthe cells. Example: 60 cells times 2.05 volts = 123 volts.

CAUTION!

FAILURE TO OBSERVE ABOVE PROCEDUREMAY IMPAIR INTEGRITY OF ELECTRICALCONNECTION AND CELL PERFORMANCE.

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CAUTION!WHEN INSTALLING TERMINAL HARDWAREDO NOT PERMIT ANY ITEMS TO FALL INTOCELL. IF SUCH MATERIAL REMAINS IN THECELL, CONTAMINATION WILL RESULT,REQUIRING REPLACEMENT OF THE CELL.

QUANTITY AND THICKNESSOF INTERCELL CONNECTORS TORQUE (INCH LBS).

1/8” or 1/4” (D cells only) 100

1/8” (M & N cells) 100

1/4” or two 1/8” (M & N cells) 150

1/4” (PDQ, N & H cells) 150

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7.7 Completing Installation

Explosion Resistant Vents

Certain cell sizes may have been shipped with Exide Pre-Vent™ vent/filling funnels in place. These vents have flexibleplastic caps installed for shipping purposes.These caps maybe removed and discarded, or they may be left in place if thebattery environment is dusty. (See Figure 3)

Other cell sizes are supplied with Pre-Vents which are notshipped in place. A standard screw-type vent is used for ship-ping purposes. If Pre-Vent units were specified, they would havebeen packed separately with other accessories. Remove thescrew-type shipping vents one-at-a-time and install a Pre-Ventunit before charging. Discard the shipping vent.

Other cell types are supplied with separate explosion resis-tant vents installed at time of shipment. Separate plastic fill-ing funnels are supplied along with this type vent. Thesefunnels also have flexible plastic shipping caps. Here again,these may be removed and discarded or left in place if envi-ronment is dusty.

The Pre-Vent assembly and other explosion resistant ventsare designed to prevent external sparks or flames from ignit-ing and exploding internal cell gases. (See Figure 4).

Electrolyte Withdrawal Tubes

Certain calcium cells are equipped with two electrolyte with-drawal tubes which are installed in the diagonal corners ofthe cell. These permit the taking of specific gravity readingsat a point about one-third from the top of the plates. (SeeSection 11.1). Refer to Figure 3.

A flexible shipping cap and shipping plug is installed on eachwithdrawal tube. The cap may be removed and discardedafter neutralizing or left in place as dust covers. The red plugshould be discarded.

Plastic Numerals (See Page 16)

Plastic cell numerals and battery terminal polarity labels areprovided for 12-cell batteries of 40 ampere hours and over.The positive terminal cell is usually designated as cell #1 inthe series string.

Battery-to-Charger Connection

The positive (+) terminal of the battery should be connectedto the positive (+) terminal of the charger and the negative(-) terminal of the battery to the negative (-) terminal of thecharger.

Battery Warning Statement and Nameplate (See Page 1)

A nameplate is shipped with the parts for each battery sys-tem. It has a peel-off backing to allow mounting on or nearthe battery. Nameplate information should be completed bythe installer at the time of the initial charge and start of bat-tery operation. The installer must make the contents of theBattery Warning Statement known to all personnel in thevicinity of the battery.

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CAUTION!

BEFORE DISPOSING OF FLEXIBLE PLASTICCAPS OR SCREW-TYPE SHIPPING CAPS,NEUTRALIZE ANY ELECTROLYTE ON THEMIN A BAKING SODA - WATER SOLUTION TOPREVENT INJURY TO ANYONE HANDLINGTHESE DISCARDED ITEMS.

Figure 4Figure 3

DUST CAPS

ELECTROLYTEWITHDRAWAL

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SECTION 88.0 Initial ChargeBatteries lose some charge during shipment as well as duringthe storage period prior to installation. The battery should beinstalled and given its initial charge as soon after receipt aspossible. At the completion of initial charge, record voltageand specific gravity of each cell while still on charge and retainrecords for future reference per Section 14.0.

8.1 Constant Voltage Method

Constant voltage is the principal method to give the initialcharge, as most modern chargers are of the constant volt-age design. In addition, some systems have equipment withvoltage limitations making the use of constant current charg-ing undesirable.

Determine the maximum voltage that may be applied to thesystem equipment. The voltage divided by the number ofcells connected in series will establish the maximum voltageper cell that may be used.

Establish whether the battery is of lead-antimony or lead-calcium construction by referring to type on cell name plateand compare this with the proper Exide sales literature.

For lead-antimony types, refer to Table A and for lead-calci-um types refer to Table B to obtain various voltages andassociated time periods recommended. Select the highestvoltage the system will allow, to perform the initial charge inthe shortest period of time.

The recommended time periods are considered minimum.Raise the voltage to the maximum value permitted by thesystem equipment. When charging current has tapered andstabilized (no further reduction for 3 hours), charge for thehours shown in the appropriate table and for the battery tem-perature, at the time of stabilization, until the lowest cell volt-age ceases to rise. Monitoring of cell voltages should bestarted during the latter 10% of the applicable time period todetermine lowest cell in battery.

INITIAL CHARGERecommended Voltages and Time Periods

TABLE ALead-Antimony Types

NOTE: Time Periods listed in tables A and B are for cell

temperatures from 70°F (21°C) to 90°F (32°C). For temper-atures 55°F (13°C) to 69°F (20.5°C) double the number ofhours. For temperatures 40°F (4°C) to 54°F (12°C) use fourtimes the number of hours.

TABLE B

Lead-Calcium Types

8.2 Initial Charge — Electrolyte LevelsDuring the initial charge, there will be an increase in theelectrolyte levels and they may go above the high level mark.(See Section 3.2).This is due to gases, that were lost during transportation orstanding in storage, being restored to the cells. Do notremove any electrolyte even though levels may be abovehigh level. When battery is placed on floating charge (SeeSection 9.2). the electrolyte levels should return close to thehigh level line.

Removal of electrolyte during the initial charge with subse-quent restoration with water of levels which have fallen fol-lowing placement on float charge mode could result in vari-ations or sub-normal specific gravity values.

SECTION 9

9.0 Operation

9.1 Floating Charge MethodIn this type of operation, the battery is connected in parallelwith a constant voltage charger and the critical load circuits.The charger should be capable of maintaining the requiredconstant voltage at battery terminals and also supply a nor-mal connected load were applicable. This will then sustainthe battery in a fully charged condition and also make itavailable to assume the emergency power requirements, inthe event of an AC power interruption or charger failure.

9.2 Float Charge — Float Voltages

The following are the float voltage ranges recommended forthe various types of batteries. Select any “volts per cell”value within the range listed that will result in the seriesstring having an average volts per cell equal to that value.Do not interchange voltage ranges from one type to another.

Time-Hrs. Time-Hrs. Time-Hrs.1.215 1.250 1.300

Cell Volts sp. gr. sp. gr. sp. gr.

2.24 444 — —2.27 333 — —2.30 210 — —2.33 148 333 —2.36 100 235 4002.39 67 160 2672.42 48 108 1822.45 38 73 1252.48 36 55 832.50 32 44 60

Time-Hrs. Time-Hrs1.215 1.250

Cell Volts sp. gr. sp. gr.2.24 200 —2.27 150 —2.30 120 —2.33 90 1462.36 75 1292.39 60 972.42 — 732.45 — 542.49 — 362.50 — 30

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TABLE C

Recommended Float Voltages

Modern constant voltage output charging equipment is rec-ommended for the floating charger method of operation ofExide stationary type batteries. This type of charger, proper-ly adjusted to the recommended float voltages, together withadherence to recommended maintenance procedures, willassist in obtaining consistent serviceability and optimum life.

After the battery has been given its initial charge (seeSection 8.0), the charger should be adjusted to provide therecommended float voltage (see Table C) at the battery ter-minals. For example, a 60-cell lead antimony battery shouldhave 130 volts maintained at its terminals. . . 60 cells x 2.17volts per cell (V.P.C.) = 130 volts.

Do not use voltages for lead-antimony types higher thanshown in table C, as excessive water consumption andreduced battery life will result.

Lead-calcium types may be floated at any of the voltage val-ues (Table C) shown for a particular nominal specific gravi-ty. Use the lower VPC value in the appropriate nominal spe-cific gravity group, where system equipment voltage limita-tions will not permit higher values. The use of higher VPCvalues may make it unnecessary to give an equalizingcharge. However, the use of higher float voltages wherehigh ambient temperatures prevail may result in reducedbattery life.

9.3 Voltmeter Calibration

Panel and portable voltmeters used to indicate battery floatvoltages should be accurate at the operating voltage value.The same holds true for portable meters used to read indi-vidual cell voltages. These meters should be checkedagainst a standard every six months and calibrated whennecessary.

9.4 Cycle Method of Operation

This method is recommended for lead antimony type cellsonly. Lead-calcium cells should not be cycle operated.

In cycle operation, the degree of discharge will vary for var-ious applications. Therefore, the frequency of rechargingwill also vary. The recharge is conducted by manually start-ing the charge, generally using the normal finish rate. Theamount of charge necessary depends on the number ofampere hours discharge. If a shorter recharge period isdesired, higher charge rates equal to the eight-hour rate ofdischarge may be used when the battery is more than 25%discharged and the cell voltage on charge is below 2.33volts.

When the cell voltage reaches 2.33, the charge rate shouldbe reduced to the normal finish charge rate. The finishcharge rate is defined as amperes equal in numerical valueto 5% of the cell’s 8-hour capacity in ampere hours. Forexample, if the cell has an 8-hour capacity of 1680 AH, itsfinish rate is 84 amperes. The charge should be stoppedwhen the specific gravity is ten (.010) points below the nor-mal fully charged value.

The battery is now available for the next discharge require-ment. The battery should be given an equalizing chargemonthly by continuing the regular charge until there is noincrease in specific gravity of the pilot cell for three hours.when using the finish charge rate.

9.5 Recharge

All batteries should be recharged as soon as possible fol-lowing a discharge (within 8 hours). With constant voltagechargers, this will be accomplished automatically. However,to recharge in the shortest period of time, raise the chargeroutput voltage to the highest value which the connected sys-tem will permit. Do not exceed those voltage values listed inTable D or Table E on page 9.

SECTION 10

10.0 Equalizing Charge

An equalizing charge is a special charge given a batterywhen non-uniformity in voltage or specific gravity has devel-oped between cells. It is given to restore all cells to a fullycharged condition using a charging voltage higher than thenormal float voltage and for a specified number of hours, asdetermined by the voltage used.

Non-uniformity of cells may result from low floating voltagedue to improper adjustment of the charger or a panel volt-meter which reads incorrect (higher) output voltage. Also,variations in cell temperatures greater than 5°F (2.78°C) inthe series string at a given time, due to environmental con-ditions or rack arrangement, can cause low cells.

10.1 Equalizing Frequency

The following guidelines cover lead-antimony and lead-calcium types. Recommendations not applying to all typeswill be so designated.

A. An equalizing charge should be given quarterly or asrequired by conditions in the following paragraphs (Note:lead-calcium types at nominal 1.215 sp. gr. floated 2.20V.P.C., to 2.25 V.P.C., nominal 1.250 sp. gr. floated at 2.27V.P.C. to 2.33 V.P.C. and nominal 1.300 sp. gr. floated at2.31V.P.C. to 2.37V.P.C.may not require equalizing charges).

B. Equalize when the temperature corrected specific grav-ity of the pilot cell (or any cell for the quarterly reading)is more than 10 points below its full charge value. (SeeSection 11.2)

C. Equalize when the floating voltage of the pilot cell (orany cell for the quarterly reading) is below 2.13 volts(nominal 1.215 sp. gr.), 2.18 volts (nominal 1.250 sp.gr.) and 2.23 volts (nominal 1.300 sp. gr.) or more than.04 volts below the average for the battery.

Lead-Antimony Types:Nominal 1.215 sp. gr. 2.15 to 2.17 VPCNominal 1.250 sp. gr. 2.19 to 2.23 VPC

Lead Calcium Types:Nominal 1.215 sp. gr. 2.17 to 2.25 VPCNominal 1.250 sp. gr. 2.23 to 2.33 VPCNominal 1.300 sp. gr. 2.28 to 2.37 VPC

D. Equalize to complete a recharge of the battery in a min-imum length of time following an emergency discharge.

E. If accurate quarterly records are maintained (SeeSection 14.0) and the individual cell voltages and teper-ature corrected specific gravities show no increaseinstead from the previous quarterly readings, equalizingmay be deferred. (See Section 11.2)

F. Equalize once a year even though preceding conditionsdid not require. (Lead-calcium types floated per para-graph A, may not require annual equalizing).

10.2 Equalizing Charge Method

Constant voltage charging is the preferred method for givingan equalizing charge. Determine the maximum voltage thatmay be applied to system equipment. This voltage, dividedby the number of cells connected in series, will establish themaximum voltage per cell that may be used to perform theequalizing charge in the shortest period of time.

For lead-antimony types, refer to Table D and for lead-calci-um type, refer to Table E to obtain various voltage and asso-ciated time period recommended.

The recommended time periods below are considered mini-mum. Raise the voltage to the maximum value permitted bythe system equipment. When charging current has taperedand stabilized (no further reduction for three hours), chargefor the hours shown in the appropriate table and for the bat-tery temperature, at the time of stabilization, until the lowestcell voltage ceases to rise. Monitoring of cell voltagesshould be started during the latter 10% of the applicabletime period to determine the lowest cell in battery.

EQUALIZING CHARGERecommended Voltages and Time Periods

TABLE DLead-Antimony Types

Time-Hrs. Time-Hrs.1.215 1.250

Cell Volts sp. gr. sp. gr.2.24 80 —2.27 60 —2.30 48 —2.33 36 582.36 30 512.39 24 392.42 — 292.45 — 262.48 — 24

TABLE ELead-Calcium Types

Time-Hrs. Time-Hrs. Time-Hr.s1.215 1.250 1.300

Cell Volts sp. gr. sp. gr. sp. gr.2.24 222 — —2.27 166 — —2.30 105 — —2.33 74 166 —2.36 50 118 2002.39 34 80 1342.42 — 54 912.45 — 36 622.48 — — 42

NOTE: Time periods listed in Tables D and E are for celltemperatures from 70°F (21°C) to 90°F (32°C). For temper-atures 55°F (13°C) to 69°F (20.5°C) double the number ofhours. For temperatures 40°F (4°C) to 54°F (12°C) use fourtimes the number of hours.

10.3 Equalizing Individual Cells

When only a few cells in a battery require equalizing, andsystem voltage limitations do not permit raising the batteryvoltage up to a recommended equalizing voltage, a separatevoltage regulated charger may be used on the affected cells.

The charger must have complete AC line isolation andshould be paralleled across the below normal cell. Selectthe equalizing voltage values listed in Tables D or E for thetype cell involved. The hours of equalizing may have to beincreased from listed values before stabilization of cell volt-age and specific gravity is achieved, especially where belownormal condition has existed for a prolonged period.

10.4 Equalizing Charge—ElectrolyteLevels

A battery which has electrolyte levels at the high level linewhile on a float and then placed on equalizing charge willresult in a rise in electrolyte above the high level line. Thisis a normal condition. DO NOT remove any electrolyte as thelevels will return to their former condition when the battery isreturned to normal float. Removal of the electrolyte withsubsequent restoration to proper electrolyte levels by wateraddition could result in variations or sub-normal specificgravity values.

SECTION 11

11.0 Specific Gravity

In a lead-acid cell, the electrolyte is a dilute solution of waterand sulfuric acid. Specific gravity is a measure of the weightof acid in the electrolyte as compared to an equal volume ofwater. Therefore, electrolyte with a specific gravity of 1.215means it is 1.215 times heavier than an equal volume ofwater which has a specific gravity of 1.000.

9

CAUTION!

WHEN INDIVIDUAL CHARGER IS REMOVEDFROM CELLWHICH HAS BEEN EQUALIZED,A DROP INVOLTAGE BELOWTHE AVERAGESTRING VOLTAGE MAY OCCUR. THIS ISNORMAL, DUE TO THE EXCESS INTERNALCELLGASESPRESENT. ASTHESEEXCESSGASES DISLODGE FROM INTERNAL CELLCOMPONENTS, THE CELL VOLTAGE WILLRISE GRADUALLY, WHICH MAY TAKE FROMTWOTOFOURWEEKS.

11.1 Hydrometer Readings

Specific gravity is used in determining a cell’s state ofcharge. It decreases as the cell discharges and increasesas the cell is charged; reaching its original value when thecell is fully charged. Specific gravity is expressed to the thirddecimal place (1.215) and is measured by a hydrometerfloat enclosed in a glass barrel/rubber bulb syringe. Drawsufficient electrolyte into the barrels holding the syringe ver-tical and with no hand pressure on bulb; so that float is freelyfloating without touching sides or top of syringe.

The gravity is read on the hydrometer scale at the flat sur-face of the electrolyte. (See Figure 5).

Clean the hydrometer glass barrel and float with soap andwater as required for ease of reading and float accuracy.

When recharging a lead-calcium cell, the specific gravityreading lags behind the ampere hour input due mainly to thevery low end of charge currents. Mixing of the electrolyte isslow due to the small amount of gas generated; so the grav-ity readings do not reflect the actual state of charge. A simi-lar condition exists after water additions. Therefore, mean-ingful gravity readings can only be obtained at the top of thecell after an equalizing charge or after six weeks on float.

For this reason, most Exide lead-calcium cells have elec-trolyte withdrawal tubes to permit sampling of the electrolyteat a point one third down from the top of the plates. A longrubber tip on the hydrometer is inserted into the tube to pro-vide an average value of cell specific gravity and a moreaccurate indication on the state of the charge.

When taking a hydrometer reading, the base of the hydro-meter syringe should be pressed firmly against the tubeopening to prevent back splash of electrolyte. Fill and emptythe hydrometer at least once in each cell before reading.This will give a more accurate reading of the average elec-trolyte density.

Never inter-mix usage of hydrometers on lead-antimony orlead-calcium types as cell contamination will result. Assignhydrometers for exclusive use on one type only.

11.2 Correction for Temperature

When taking specific gravity readings, corrections must bemade for variations in temperature of the electrolyte. Foreach 3°F (1.67°C) in temperature of the electrolyte above77°F (25°C) add one point (.001) in specific gravity to theobserved hydrometer readings; and for each 3°F (1.67°C) intemperature below 77°F (25°C) subtract one (.001) in spe-cific gravity from the observed hydrometer reading.

Example:Reading

Hydrometer Cell Corrected toReading Temperature Correction 77°F (25°C)

1.213 sp. gr 68°F (20°C) -.003 points= 1.210 sp. gr.1.207 sp. gr. 86°F (30°C) +.003 points= 1.210 sp. gr.1.204 sp. gr. 95°F (35°C) +.006 points= 1.210 sp. gr.

11.3 Correction for Electrolyte Level

The loss of water from the electrolyte due to evaporation aswell as conversion of the water to hydrogen and oxygen bycharging current also effects the specific gravity value. Forexample: A fully charged cell with a correct high level at77°F (25°C) will have a nominal specific gravity of 1.215.When the electrolyte level has been reduced from evapora-tion and charging by 1/4”, the specific gravity will be approx-imately 6 points (.006) higher or 1.221@ 77°F (25°C).Therefore when taking hydrometer readings, the electrolytelevel referenced to the high level line should be recorded forproper evaluation of the specific gravity value. This applieswhen taking a pilot cell reading or for 10% of the cells whentaking a quarterly set of readings.

11.4 Specific Gravity Range

Exide stationary batteries are furnished with a nominal fullycharged specific gravity of 1.215@ 77°F (25°C).

For special applications, nominal specific gravity such as1.250 or 1.300 @ 77°F (25°C) may be used.

The specific gravity may range± .010 points within a batteryfor any of the nominal values @ 77°F (25°C) with the elec-trolyte level at the high level line and still be considered sat-isfactory.

SECTION 12

12.0 Cell Voltage Variation

The tabulation on the following page indicates the normal cellvoltage variation that may exist with the battery on float andno greater than a 5°F (2.78°C) variation in cell temperature.

10

Figure 5

NORMAL VOLTAGE RANGE

AverageType Float Voltage Variation

Lead-AntimonyNominal 1.215 sp. gr. 2.15 to 2.17 V.P.C. ± .04 V.P.C.Nominal 1.250 sp. gr. 2.19 to 2.23 V.P.C. ± .04 V.P.C.

Lead-CalciumNominal 1.215 sp. gr. 2.17 to 2.25 V.P.C. ± .05 V.P.C.Nominal 1.250 sp. gr. 2.23 to 2.33 V.P.C. ± .05 V.P.C.Nominal 1.300 sp. gr. 2.28 to 2.37 V.P.C. ± .05 V.P.C.

12.1 Cell Voltage VariationDamp Covers

Cell voltage variation can also be the result of damp cell covertops. Spilled electrolyte when taking hydrometer readings canresult in parasitic currents paths across the tops of cell covers.This reduces the float current through the cell resulting in volt-age variations. See Section 18.0 - Battery Cleaning—to correctdamp cover condition.

12.2 Cell Voltage -Temperature Correction

To properly analyze cell uniformity within the string, cell voltagesshould be corrected for cell electrolyte temperature. Cell voltagevariation that may have developed since a previous quarterly setof readings may be due to cell temperature variations within thestring that may have resulted from a change in ambient condi-tions. Therefore, correcting cell voltage for cell temperature maymake it unnecessary to apply an equalizing charge which oth-erwise had been believed necessary. See Section 10.1 -Equalizing Frequency.

12.3 Correction Factor

The temperature correction factor for cell voltage equals 0.003volts for each degree fahrenheit (0.0055V/C°) using a base 77°F(25°C). The correction is added to the measured cell voltageabove 77°F (25°C) and subtracted below 77°F (25°C).

Example: Measured cell voltage = 2.19V @ 87°F(30.5°C) celltemperature. Correction = 10°F x .003V (3.5°C x .0055V) =.03V. Therefore, corrected cell voltage = 2.19V + .03V = 2.22volts.

If the cell temperature in the example had been 67°F (19°C), thecorrection would be .03 volts which is subtracted from the mea-sured voltage of 2.19V. The corrected cell voltage = 2.19V - .03V= 2.16V.

SECTION 13

13.0 Pilot Cell

A pilot cell is selected in the series string to reflect the gen-eral condition of all cells in the battery regarding specificgravities, float voltage and temperature. It serves as an indi-cator of battery condition between scheduled overall indi-vidual cell readings.

A slight amount of electrolyte may be lost each time a specificgravity reading is taken, even though it is recommended that allelectrolyte in the hydrometer be returned to the cell after read-ing. Therefore it is suggested that the pilot cell be changed toanother cell annually to provide a representative specific gravityindicator for the battery.

SECTION 14

14.0 Records

A complete recorded history of the battery operation isrequired. Good records will also show when correctiveaction may be required to eliminate possible charging, main-tenance or environmental problems.

Data should be recorded on Stationary Battery MaintenanceReport shown on page 15. Report headings should be filledin completely on the date of installation.

The following data should be read and permanently record-ed for review by supervisory personnel.

A. Upon completion of the initial charge and with the batteryfloating at the desired float voltage for one week, readand record individual cell voltages, connection resis-tances, specific gravities [corrected to 77°F (25°C)],ambient temperature plus cell temperatures and elec-trolyte levels for 10% of the cells. The cell temperaturereadings should be from each step or tier of the rack toreflect temperature range of the battery.

This first set of readings will be the basis for comparisonwith subsequent readings to reflect possible operatingproblems and the need for corrective action.

B. Monthly - Observe the general appearance and cleanli-ness of the battery. Record battery terminal voltage.Check electrolyte levels and adjust if necessary. Checkfor cracks in cells and leakage. Note any evidence of cor-rosion at terminals and connectors. Record pilot cell volt-age, specific gravity and temperature.

C. Quarterly - Supplement the monthly inspection andrecord keeping with these additional measures. Checkand record the specific gravity and voltage of each cell.Check and record the electrolyte temperature of one cellon each level of individual racks.

D. Annual - Supplement quarterly reports with these extraprocedures. Make a detailed visual inspection of eachcell. Tighten all bolted connections to the specifiedtorque values. Take and record connection resistancesof each cell to cell, cell to terminal, inter-level and loadconnections. Remake any connections that are morethan 20% above installation base value. Check integrityof the rack.

E. Any time the battery is given an equalizing charge (seeSection 10.1), an additional set of individual cell readings

11

should be taken after battery has been returned to normalfloat for one week. These will serve as an updated basis forcomparison with future readings.

F. Record dates of any equalizing charges as well as totalquantity of water when added. Also record any mainte-nance and/or testing performed.

The foregoing frequency of record taking may have tobe modified somewhat to suit local requirements.

See Page 16 for Battery nameplate

SECTION 15

15.0 Water Additions

There are two conditions in the operation of batteries whichcause a reduction in the amount of water in the electrolyte,resulting in a lowering of the electrolyte level. These arenormal evaporation and the conversion of water into hydro-gen and oxygen gases by the charging current.These gasesare liberated through the cell vents. Periodically, this waterloss must be replaced with approved or distilled water tomaintain the electrolyte level at the mid point between thehigh and low level lines.

If suitability of the local water supply for use in storage bat-teries is questionable, contact your nearest Exide represen-tative for instructions regarding procedure for submitting asample for analysis. A report will be rendered as to whetheror not the water is suitable.

If water is to be stored in containers they should be cleanand of non-metallic material; such as: glass, hard rubber,porcelain or plastic.

Infrequently used water lines should be purged to removeaccumulated impurities, thus preventing their introductioninto the battery.

Water additions should be scheduled prior to an equalizingcharge so that mixing with the electrolyte occurs. Also atunheated installations, arrange water additions when bat-tery temperature is above 50°F (10°C).

Never introduce “battery additives” into a Exide battery.

15.1 Water Purity

The maximum allowable limits of impurities in the waterused in Exide stationary batteries shall be as follows:

Total solids 500 ppmFixed solids 350ppmOrganic & volatile matter 200ppmIron as Fe 4.0 ppmManganese as Mn 0.007 ppmNitrates as N02 15.0 ppmAmmonia as NH4 5.0 ppmChlorides as CL 25.0 ppm

Distilled water or deionized water satisfying the aboverequirements may be used.

SECTION 16

16.0 Tap ConnectionsIt is not recommended that tap connections be used on abattery, as possible unbalance between groups of cells mayresult. This can cause overcharging of the untapped groupof cells and undercharging of the tapped cells supplying theload. This condition can cause unsatisfactory operation andreduced battery life.

SECTION 17

17.0 Temporary Nonuse

An installed battery that is permitted to stand idle for a peri-od of time should be treated in the following manner. Withthe battery on normal float, add approved water to cells tobring electrolyte level to the high level line. Give the batteryan equalizing charge per Section 10.2. Following comple-tion of the equalizing charge, open connections at the bat-tery terminals to separate charger and load circuit from bat-tery.

Every three months for lead antimony and every six monthsfor lead calcium, temporarily connect battery to charger andgive it an equalizing charge.

To return to normal service, re-connect all open connec-tions, give equalizing charge and then return battery to nor-mal float voltage.

SECTION 1818.0 Battery Cleaning

18.1 Styrene Acrylonitrile Containerswith Butadiene Styrene Coversand PVC Containers and Covers

Periodically, clean cell jars and covers with a water damp-ened cloth to remove accumulated dust. Cell parts dampwith electrolyte should be neutralized with baking soda-water solution (1 lb. of soda per gallon of water). Apply withcloth dampened with the solution, making sure none isallowed to enter the cell. Continue to neutralize until fizzingaction ceases, then wipe area with a water dampened clothto remove soda solution. Wipe dry with a clean cloth.

18.2 Polycarbonate Containersand Covers

Cells with containers and covers made from polycarbonateplastic should be cleaned ONLY with a WATER dampened

CAUTION

DO NOT CLEAN PLASTIC CELL JARS ORCOVERS WITH SOLVENTS, DETER-GENTS, OILS OR SPRAY TYPE CLEAN-ERS, AS THESE MATERIALS MAY CAUSECRAZING AND CRACKING OF THE PLAS-TIC MATERIALS

12

cloth. Any surface that is damp with electrolyte should beneutralized with a baking soda—water solution (1 lb. of bak-ing soda per gallon of water). DO NOT USE AMMONIA,SODIUM HYDROXIDE OR ANY STRONG ALKALIES.

SECTION 19

19.0 Connections

Battery terminal connections should be corrosion free andtight to provide satisfactory operation while supplying emer-gency power and when on floating charging.Visual monitoring of all connections should be made quar-terly. When corrosion is observed on any connection, DONOT retorque. Retorquing does not improve electricalintegrity but only restores mechanical compression. Anyconnection suspected of having corrosion should be disas-sembled, cleaned and neutralized. All post contact sur-faces, intercell connectors, terminal plates, cable lugs andhardware should be neutralized using a solution of bakingsoda (1 lb./gallon water). After allowing to dry, all contactsurfaces should be burnished using 3M Scotch Brite scour-ing pads or a brass suede brush. Stubborn oxidized coat-ings on solid lead parts may be removed using a narrow

paint scraper.After contact surfaces are burnished, a thin coating of NO-OX-ID grease should be applied to all contact surfaces andhardware. The connectors and hardware should then bereassembled and torqued per Section 7.6 - ConnectingCells.

It is important that properly prepared contact surfaces becoated with a thin film of NO-OX-ID grease to reduce possi-bility of oxidation or corrosion. Tests reveal that this will alsoprevent measurable increase in the connection resistance.

19.1 Connection Resistance

Electrical integrity of connections can be objectively estab-lished by measuring the resistance of each connection.These resistances are typically in the microhm range.Meters are available which determine connection resistancein microhms by measuring voltage drop upon the applicationof a fixed direct current (DC) through the external cell con-nections. Some precautions must be observed to get con-sistent and meaningful values, however, and these aredescribed in Section 19.3.

13

Resistance measurements or microhm measurementsshould be taken at the time of the installation and annuallythereafter. Initial measurements at installation become thebenchmark values and should be recorded for future moni-toring of electrical integrity.

Specific values of connection resistance vary with cell type,quantity of connectors, etc. It is important that the bench-mark value for all similar connections should be no greaterthan 10% or 5 microhms, whichever is greater, above theaverage resistance of all such connections in the battery. Ifany connection resistance exceed the average by more than10% or 5 microhms, whichever is greater, the connectionshould be remade so that an acceptable benchmark valueis established. Benchmark values for connection resis-tances should also be established for terminal plates, whereused, as well as cable connections. Benchmark valuesshould preferably be established upon installation. However,if that was not done, they may be established later providedthe special procedure described below is followed.

Disconnect the battery from the charger and load and dis-assemble at least three (3) of the intercell connections.Clean, neutralize and burnish these connection componentsas though they had corrosion (See Section 19.0)Reassemble each connection per Section 7.7 and deter-mine its resistance. Measure the resistance of all similarconnections in the battery. If any connection resistanceexceeds the average of the three remade connections by10% or 5 microhms, whichever is greater, that connectionshould be remade to establish an acceptable benchmarkvalue.

All benchmark values should be recorded. Annually, all con-nection resistances should be remeasured. Any connectionwhich has a resistance value more than 20% above thebenchmark value should be corrected.

Increase in connection resistance of more than 20% abovethe recorded benchmark definitely indicates a degradingconnection. Such degradation may be caused by corrosion(See Section 19.0) or by relaxation in hardware torquevalue. If there is no sign of corrosion, the higher resistanceat the connection may be corrected by retorquing (SeeSection19.2). If connection resistance is reduced to within20% of the benchmark value, no further action will be nec-essary. Failure to restore resistance to an acceptable valuewill necessitate reworking the connection.

Maintaining electrical integrity of connections is importantas poor connection will result in reduced battery output andin extreme cases may cause melted cell posts, circuit inter-ruptions or battery fires.

19.2 Retorquing Connections

Retorquing of connections should be performed annually(See Section 9, 14) and when connection resistances haveincreased to more than 20% over the benchmark.Retorquing should not be done if visual inspection showsevidence of corrosion. Retorquing when corrosion is pre-sent only restores mechanical compression but will notimprove electrical integrity.

CAUTION!

1 DO NOT USE POWER WIRE BRUSH ASTHIS MAY REMOVE LEAD PLATINGEXPOSING COPPER OR CAUSE RIP-PLING OF LEAD CONTACTSURFACES.

2.. DONOT USE PAINT SCRAPER ON POSTSWITH COPPER INSERTS. INTERCELL CON-NECTORS OR TERMINAL PLATES AS LEADPLATING WILL BE REMOVED EXPOSINGCOPPER.

Tests reveal that a reduction in the original torque value of30% still provides a functional electrical connection if thereis no corrosion between contact surfaces.

Retorquing of connections should always be to the recom-mended value (See Section 7.7).

19.3 Connection ResistanceMeasurements

Connection resistances are very small, usually in microhms.Therefore, precautions must be observed so that the mea-sured values are meaningful and not misleading. Differentconnector hook-ups require that the measurement tech-nique allows for these differences.

(i) Single Connector Hook-ups. (Figure 6)

When measuring the resistance of single connec-tor hook-ups between adjacent cell posts (or in thecase of flag terminals between multi-cell units), theprobe point locations must be at the same locationfor each similar type connection. If the probe partdeparts from the center point indicated by “X” inFigure 6, the measured resistance value can varydue to either an increase or decrease in the leadmass included in the measuring points.When con- ducting subsequent monitoring ofconnection resis-tance, it is important that the sameprobe pointlocations are used so that any measured increase(or decrease) is a true increase (or decrease) due toconnection degradation and not due to using a dif-ferent probe point location.

(ii) Parallel Connector Hook-Ups.(Figure 7)

Parallel paths exist in this hook-up and measure-ment of connection resistance include all four con-nector post interfaces. The location of probe pointsis not critical here because of the existence of paral-lel paths. An increase (decrease) in the lead massbetween post and connector interface on one side iscancelled by an equal decrease (increase) in themass on the opposite side.

(iii) Four Post, Four Connector In-Line Hook-Ups.(Figure 8)

Cells with four post connector hook ups require twomeasurements to monitor all eight post-connectorinterfaces. Measurement is made in two steps—First between points A and C and then betweenpoints B and D. The measured values should be thesame. Values appreciably different (5 micrhoms ormore) require reworking of connections asdescribed in Section 19.0.

(iv) Four Post, Two Connector Staggered Hook-Ups.(Figure 9).

Cells with four post staggered connector hook-upsrequire two step measurement as described above in(iii). In addition, the probe point locations for points Aand D (See Figure 9) must be centered as describedabove in (i).

(v) Four Post, Connector Parallel Hook-Ups.(Figure 10)

Cells arranged end-to-end have parallel current pathsabove and below the cell covers and require that resis-tance measurement make allowance for the same. Thecurrent paths above the cover are provided by the con-nectors and the path under the cover is provided by thebusbars (shown by dotted lines in Figure 10). Mostresistance meters apply 10 amperes DC to the connec-tions being monitored. If this was done between postsA and B in Figure 10, the current will divide through thebusbars between AB and CD and the resistance valuewill be about half of the actual value, provided all con-nections are good. If the process is repeated for postsC and D and the two resistance values are compared,the difference, if any, indicates differences in the twoparallel paths as well as poor connections at the postconnector interfaces. A better and preferred techniqueis to apply the 10 amperes DC to posts A and D suchthat equal current paths are provided. Then, the differ-ences in readings across AB and CD will reflect con-nector interface problems in either of the two externalintercell connections. Both intercell connections shouldbe reworked as described in Section 19.0.

CAUTION!

TOO FREQUENT RETORQUING OFCONNECTIONS IS NOT RECOMMEND-ED AS THIS WILL RESULT IN DISTOR-TION OF CELL POSTS, CONNECTORS,ETC., THUS DEGRADING RATHERTHAN IMPROVING THECONNECTIONS.

14

Figure 6 Single connector hook-ups

Figure 7 Parallel connector hook-ups

Figure 8 Four post, four connector in-line hook-ups

Figure 9 Four post, two connector staggered post hook-ups

Figure 10 Four post, four connector parallel hook-ups

15

GB-1000F

INDUSTRIAL ENERGY

TECHNOLOGIES

Exide Technologies Industrial Energy

To insure proper adhesion of the pressure sensitive plasticcell numerals, and polarity markings supplied with yourExide Stationary Battery, the following procedure should befollowed:

1. Numerals and polarity markings should not be applieduntil after the cells have been installed on the rack. It isrecommended that they be applied to jar surfaces only,and not to cell covers or rack rails.

2. Clean the plastic jar surface, in the area where thenumeral is to be located, by using a cloth dampenedwith a washing soda solution. Immediately dry the areausing a soft dry cloth to remove residual washing soda.CAUTION!! Do not use any solvent type materials asthey may cause damage to the plastic jar material.

3. It is a general practice to designate the positive terminalcell as #1 with succeeding cells in series in ascendingorder.

4. Numerals are shipped mounted on a plastic backingstrip. They are easily removed by peeling back the plas-tic strip. Keep finger contact with adhesive backing onnumeral to a minimum.

5. Locate and place numeral on side of jar, being carefulthat there is no conflict with electrolyte level lines or siderails of SEISMIC TYPE RACKS. For clean appearance,exercise care in numeral placement so that all thenumerals are in the same relative position on each cell.

Install polarity markings on the appropriate cells in thesame manner.

6. Following application of cell numerals and polarity mark-ings, use a dry cloth to rub entire surface of each labelto insure proper surface contact.

Note: Design and/or specifications subject to changewithout notice. If questions arise, contact your localsales representative for clarification.

16

STATIONARY BATTERY PLASTIC CELL NUMERAL APPLICATION

TYPICAL BATTERY NAMEPLATE

NOTES

NO. OF CELLS TYPE SERIAL NO.

CAPACITY AMPERE HRS. AT HR. RATE

SPECIFIC GRAVITY

EX DE TECHNOLOGIES INDUSTRIAL ENERGY, Aurora, IL 60504

INDUSTRIAL ENERGY

TECHNOLOGIES

Exide Technologies –The Industry Leader.

SECTION 93.10 2010-03INDUSTRIAL ENERGY

TECHNOLOGIES

Exide Technologies Industrial EnergyUSA – Tel: 888.898.4462Canada – Tel: 800.268.2698

www.exide.com

®

Exide Technologies Industrial Energy is a global leader in

motive power battery and charger systems for electric lift

trucks and other material handling equipment. Network

power applications include communication/data networks,

UPS systems for computers and control systems, electrical

power generation and distribution systems, as well as a wide

range of other industrial standby power applications. With a

strong manufacturing base in both North America and Europe

and a truly global reach (operations in more than 80 countries)

in sales and service, Exide Technologies Industrial Energy is

best positioned to satisfy your back up power needs locally

as well as all over the world.

Basedonover 100 years of technological innovation theNetworkPower Division leads the industry with the most recognizedglobal brands such as ABSOLYTE®, GNB FLOODEDCLASSIC®,MARATHON®, ONYX™, RELAY GEL®, SONNENSCHEIN®, andSPRINTER®. They have come to symbolize quality, reliability,performance and excellence in all the markets served.

Exide Technologies takes pride in its commitment to a betterenvironment. Its Total Battery Management program, anintegrated approach to manufacturing, distributing andrecycling of lead acid batteries, has been developed to ensurea safe and responsible life cycle for all of its products.