INSTALLATION

&
OPERATION MANUAL

LOW MAINTENANCE LEAD ACID BATTERIES

For NDP, HDP & SPV APPLICATIONS

HBL POWER SYSTEMS LTD.

Survey No. 155 / 1 & 156 Part,
Sheripally (B) (V), Boothpur (M)
Mahaboob Nagar (D), Andhra Pradesh 509382

CONTENTS
PAGE
1.

INTRODUCTION

01

2.

SAFETY PRECAUTIONS

03

3.

RECEIVING THE SHIPMENT

03

4.

STORAGE

04

5.

UNPACKING

05

6.

INSTALLATION

05

7.

PREFERED FACILITIES FOR TREATMENT/FOR

INSTALLATION & OPERATION OF LOW
MAINTENECE LEAD ACID BATTERIES

08

POWER PLANT COMPATIBILITY / SELECTION

OF CHARGER

08

9.

CHARGING

10

10.

PERFORMANCE OF BATTERIES

18

11.

DOS AND DONTS

24

12.

WARRANTY CONDITIONS

25

13.

MAINTENANCE

28

14.

SPECIAL MAINTENANCE INSTRUCTIONS

31

8.

Please read the instructions given in this manual to obtain the optimum
(best) performance and life out of Low Maintenance Lead acid batteries.
Precautions pertaining to installation, commissioning and operating of
these batteries given in various sections of this manual (Following
precautions) should be strictly followed.

AD

TU
RN

LE

RE

RECYCLE

Disposal Action
Pb

After completion of service life, batteries should not be dumped or

incinerate to environment. Contact HBL for disposal action.

1.0 INTRODUCTION
HBL backed by its core strength as R&D has been continuously
updating its designs with the latest advancements for various
applications.
Products from HBL have been in use in sectors of Telecom,
Industry, Defence, Railways, Aviation and are well designed to meet
the rigorous working conditions.
1.1

SPECIAL FEATURES OF LOW-MAINTENACE CELLS / BATTERIES

Special alloy for grids to minimize water loss & self-discharge.
High impact resistance PPSFM / Rugged Hard rubber containers
& covers
Reduced frequency of water topping up.
High charging efficiency
Low self-discharge
Long service life under deep cycle usage.
Low maintenance lead acid cells / batteries consists of Tubular
positive plates, Pasted negative plates and micro porous separators
assembled in high impact resistance PPSFM / Rugged Hard rubber
containers and covers. Each cell provided with bolted type
terminals, Micro porous vent plugs and float guides.

1.2

TUBULAR POSITIVE PLATE

Spine grids are made of corrosion resistant Lead alloy and are
pressure diecasted. Multi-tubular bags fitted to grids have high
outstanding (better to replace with some other word) characteristics
of porosity, acid resistance, oxidation resistance and high rupture
(word "puncture" may be more appropriate) strength. This design
of tubular positive plate enable the active material to be retained
within the bags so that shedding is restricted during its service life.

1.3

PASTED NEGATIVE PLATES

Consists of grids with ribbed structure made from lead alloy and
having pockets, which hold the active material firmly. The active

2
material is prepared under controlled conditions with necessary
additives for an efficient electrical performance of the cell / battery
including features of long service life.
1.4

MICROPOROUS SEPARATORS
The separators used have high porosity, low electrical resistance
for ionic flow and high oxidation resistance.

1.5

CONTAINER AND COVERS

The PPSFM / Rugged Hard rubber containers and covers which
hold plate stacks (element groups) are Sturdy, Vibration resistance,
High impact strength and Low acid permeability.

1.6

MICROPOROUS VENT PLUGS

Micro porous vent plugs minimize evaporation of water from the
cell / battery and the porous structures trap the escaping water
vapour and allow only gases to go out.

1.7

FLOAT GUIDES / LEVEL INDICATERS

An acid level-indicating float guide with level marking is located at
the top of each cell for showing the acid level.
HBL Batteries conform to IS 1651:1991 specifications and have
been tested & approved by Govt Labs such as CECRI, ETDC and
ERTL. Capacities of these batteries are designated at 10 hr
discharge rate, to an end voltage of 1.85 Volts/cell, at an ambient
temperature of 27C, which is referred to as the nominal capacity
of the battery and is expressed in Ampere-hours (Ah).
HBL Batteries are designed to provide trouble free service when
used in accordance with the guidelines & instructions given in this
booklet.
For further help or clarifications please contact our nearest
Customer Service centres. (Addresses provided at the rear side of
this manual).

Toll free number 1800-425-2939

2.0 SAFETY PRECAUTIONS

Only authorized and trained personnel familiar with battery
installation, operation and maintenance should be permitted to work
on the battery.
Following precautions should be followed for the safety of the
operator and also of the battery system.
z Do not touch inter cell connectors or terminals of the battery
without wearing gloves.
z Isolate the battery from the Charger / Load while working on the
battery to avoid sparks.
z Use only insulated tools for maintenance of battery to avoid any
accidental shorting.
z Remove metal wristbands, chains, and loose coins from shirt /
pockets while working on the battery to avoid any accidental
shorting.
z Do not allow metal objects to rest on the battery or fall across
the terminals
z Do not expose the battery to open flame or sparks.
z Do not tamper with cell vent plug.
z Ensure that the connections are made as per the General
Arrangement (G.A) enclosed.
z Do not attempt to move the installed battery without removing
inter cell/module connectors.
z Keep the battery clean and dry.
z In case of accidental contact with acid, wash the affected area
with a continuous flow of water for 15 minutes and consult doctor
immediately.

3.0 RECEIVING THE SHIPMENT

Cells / batteries are packed in separate packing boxes.
3.1

Unloading the shipment

z Use forklift or portable crane or chain pulley block or any other
suitable material handling equipment

4
z If unloaded manually, the packing boxes should be handled
carefully. Do not drop on to the ground.
z Do not handle more than one box at a time.
3.2

Receiving the shipment

z Inspect the packing boxes carefully for any transit damages.
z Check the shipment as per the packing list including electrolyte
qty. and Sp.gr.
z If there is any damage during transportation of short shipment
of any item, then make a detailed Note of it in the delivery receipt
before you accept the shipment. Inform the same to HBL Power
systems ltd within 15 days so that the insurance claim can be
made and the damaged material can be replaced. Delay in
informing may result in loss of right to reimbursement for
damages.
z If transit damages are notified after storage, warranty claims
will not be entertained.

4.0 STORAGE
If the batteries are not to be used immediately, they should be stored
in a cool, dry location, protected from direct sunlight and rain. If
batteries are to be stored in packed condition, packing boxes should
be placed on the floor in the upright position as indicated by the
direction arrows. Do not keep the packing boxes one on top of the
other since this may cause damage to the batteries.
4.1

STORAGE PERIOD
z HBL batteries are supplied in DRY and UNCHARGED condition
and can be stored for a maximum period of 2 Years under shelter.
z It is not recommended to store the batteries after electrolyte
filling and initial charging. If stored, because of whatever reason,
storage period shall not exceed 3 months @ 27 deg. C.
z If storage period exceeds 3 months @ 27 deg. C, then freshening
charge should be given as detailed in section 9.3.
z It is advisable to reduce the storage interval between freshening
charges, when there is a doubt in estimating the average ambient
temperature during storage.
z Ensure that the service record is duly filled in when the battery
is given a freshening charge.

5
Note: Frequency of giving equalizing charge shall be increased by
two times for every 9 to 10 deg. C rise in operating temperature i.e.
for every 1.5 months if operating temperature is 36 deg. C.

5.0 UNPACKING
Cells / batteries are packed in wooden packing boxes, which are
internally lined with shock absorbing Materials. Each battery is
packed in a separate packing box. A separate packing case
containing accessories is provided with every battery bank.
For easy unpacking of batteries without causing damage to the
cells / batteries, the following step-by-step instructions have to be
followed.
z Cut the metallic strap of the packing box with the help of a
cutter or a plier.
z Slowly turn the packing box over so as to make the packing
box sitting on its side.
z With the help of chisel and hammer, open and remove the
bottom of packing box.
z Slowly turn the packing box so that the packing box is in
upright position.
z Slowly lift the packing box with the help of side planks provided
on the packing box.

6.0 INSTALLATION
Install batteries on the battery stands. After ensuring that, the cells
are in perfect level, tighten the connectors securely as per the G.A.
drawing using insulated tools.
Visually check that all connections have been made as per the
G.A. drawing. Also check the open circuit voltage (OCV) of all the
cells / batteries. Total OCV of the battery bank should be equal to
the sum of individual OCVs of all the cells / batteries.
6.1

CELL ARRANGEMENT
Before assembling, please refer the G.A drawing, for the number
of cells to be stacked and polarities.

6
z Lift the cells / batteries slowly and place it on the battery stand.
z Care should be taken while lifting cells / batteries to avoid
slipping.
6.2

ELECTRICAL CONNECTIONS

6.2.1 Preparation of cell terminals for electrical connections

Surfaces of the terminals should be free from dust, tarnish etc.
They should be removed, if present, with dry cotton cloth. Do not
use abrasive brush or steel brush.
6.2.2 Connector installations
Polarity marks are terminals (moulded on the lid) of each cell. For
easy identification terminals top surface are coloured (Red is for
positive, Blue is for negative)
Assemble the inter cell connections, using insulated tools.
6.2.3 Inter row connections
Connect the rows using inter row flexible connectors fitted with
end cell connectors as per the General Arrangement Drawing.
Note: It is the sole responsibility of the user to check the
connections. All connections should be checked at regular
intervals to ensure that the connections are clean and tight.
Never operate a battery with loose or corroded connections.
While checking connections, disconnect the battery from the
load and the charging equipment, and follow all precautions
outlined above. While installing inter cell connectors, do not
drop the cell connectors on to the terminals
6.3

ELECTROLYTE FILLING AND INITIAL CHARGING

Clean the cells, vent plugs and terminals to remove dust and any
other extraneous materials prior to proceeding for electrolyte filling
and initial charging.

7
6.3.1 Preparation of electrolyte
z Use battery grade sulphuric acid conforming to IS: 266 (latest
issue). Refer to the "Acid mixing" table given below for making
sulphuric acid of desired specific gravity.
z Concentrated sulphuric acid shall be added to distilled water
slowly with constant stirring.
z While mixing, the acid temperature increases. Allow the acid to
cool down to room temperature.
z Stirring shall be done while taking acid for Filling
Note: To get the electrolyte of desired specific gravity, concentrated
sulphuric acid should not be diluted by adding distilled water
as will lead to accidents (may result in explosion).
6.3.2 Electrolyte filling
z Remove the vent plugs and fill with the electrolyte until the float
guide touches the green mark in transparent indicator.
z Quantity and specific gravity of electrolyte used for filling of new
cells / batteries shall be as specified in the following table:
Type of battery Electrolyte specific gravity Quantity of electrolyte to be filled
NDP series

1.1800.005@27 deg.C

Refer the GA drawing

HDP series

1.1800.005@27 deg.C

-do-

SPV series

1.2200.005@27 deg.C

-do-

Note: Above stated specific gravities are applicable for an operating

temperature of 27 deg. C. If, temperature varies from 27deg.
C, electrolyte specific gravity to be used for filling shall be
arrived with the following empirical formula:
S.G.T = S.G 27 / (1+0.00007 x (T-27))
Where
S.G.T = Specific gravity of electrolyte at an operating temperature
of T deg. C
S.G 27 = Specific gravity of electrolyte at 27 deg. C
T

= Operating temperature in T deg. C

8
z After electrolyte filling, the cells / batteries shall be allowed to
be under rest for 12 to 24 hrs
z After completion of the rest period, if level indicator falls below
the lower level in transparent indicator, it should be adjusted by
adding some more electrolyte of same specific gravity used for
filling prior to proceeding for charging.

7.0 PREFERED FACILITIES FOR TREATMENT / FOR

INSTALLATION & OPERATION OF LOW MAINTENECE
LEAD ACID BATTERIES
z Battery room shall have adequate ventilation (Preferably in
ground floor for easy handling of cells / batteries)
z Flooring shall be lined with acid resistant tiles
z Chargers of appropriate ratings required for initial charging and
subsequent charging with voltage & current selection (Refer
Section 8.0 for guidelines related to charger / power plant).
z Calibrated Digital ammeter, Digital Voltmeter, Digital
Thermometer and Hydrometer
z Sulphuric acid used for electrolyte preparation shall be of battery
grade and shall conform with the requirements of IS: 266
specification (latest issue).
z Distilled water used for diluting sulphuric acid (during electrolyte
preparation) and topping up for adjusting the electrolyte level
while the battery is under operation shall conform with the
requirements of IS: 1069 specification (latest issue).
z Material handling equipment - Trolleys / Fork lift
z Insulated tools (Spanners, L-Handles, Torque wrenches etc.)
z Safety tools like Rubber boots, Rubber Apron, Rubber Gloves,
Syringe & Spectacles Forced water for cleaning battery.

8.0 POWER PLANT COMPATIBILITY / SELECTION OF

CHARGER
8.1

CONSTANT CURRENT CHARGER

Constant current charger with charge current required for the
batteries have to be selected Based on the:

9
z Number of Cells / batteries required to be charged per cycle
based on the operation demands
z The charger voltage to be considered 3V per cell ( e.g. If the
number of 2V cells to be charged is 60 nos, the charger to be
capable attaining 180 Volts)
z Charger current rating 10 to 15 % extra than the current values
given in table in order to avoid operating the charger at full load
z Ripple content shall be kept to minimum (Preferably less than
3%)
z Built in resistive load for discharge can be considered or Load
banks can be used for discharge
8.2

CONSTANT VOLTAGE / POTENTIAL CHARGER

Constant voltage power plants, which have the following features:
z Individual voltage settings in Float, Boost and Equalizing
charging modes
z Auto change over facility from Float to Boost and vice versa
z Should have temperature compensation circuit (for adjusting the
charge voltage based on battery temperature).
z Should have the provision to set the Battery path current limit
and it should be adjustable in between 10-20% of Battery Ah
capacity.
z Output voltage should be stable with a regulation of + 0.1 V
considering the fluctuations in load & mains supply.
z Should have calibrated measuring instruments.
z Ripple should be less than 3% RMS.
z Provision of Low Voltage disconnect/indication/alarm to isolate
the battery
z Voltage feed back sensors shall be drawn from:
-

For controlling charge voltage: Should be directly taken from

battery terminals.

For low voltage disconnect: Should be taken from the bus bar
of the power plant.

10
8.3

INSTALLATION OF CHARGER
z Charger to be protected against acid attack by providing partition
between battery charging and charger
z The distance between the charger and battery under charge to
be kept minimum to avoid loss of energy and proper charging of
cells/batteries

9.0 CHARGING
9.1

INITIAL CHARGING
z DC charger having ripple < 3 % of RMS shall only be used for
charging.
z Please remove vent plugs and float guide during initial charging,
initial cycling to avoid the container bulging due to the excess
gas generation.
z Connect the cables from the battery charger to the end terminals
of the battery system with correct polarity i.e. charger's positive
to battery positive and charger's negative to battery negative.
z Measure and record the open circuit voltage (OCV) of all the
cells / batteries. Total OCV of the battery should be equal to the
sum of individual OCV's of all the cells / batteries.
z For cells / batteries made and supplied with unformed plates:
Measure and record the cell voltages within a maximum period
of 15 minutes after starting the charging. Ensure that, cell /
battery voltages are measured with correct polarity i.e. by
connecting positive probe of multimeter on to cell's/battery's
positive terminal and vice versa.
Check, if there are any cells / batteries connected in series with
reverse polarity. If, observed correct the connections and resume
the charging.
z During charging, voltage, specific gravity and electrolyte
temperature of each cell / battery shall be measured and
recorded once in 4 hours until cell / battery voltage reaches up
to 2.40 V/cell and there after for every 1 hour.

11
z The cells / batteries are said to be fully charged when cell /
battery voltage and specific gravity values remain constant (with
minimal variation, Voltage: +/- 0.010 V and Specific gravity +/0.005) in 3 consecutive hourly readings.
z If electrolyte temperature of the cell / battery rises above 50C,
charging should be stopped and cells / batteries shall be allowed
to be under rest until the electrolyte temperature comes down
to 35C there after charging shall be resumed.
z Throughout the initial charging, electrolyte level shall be
maintained up to the maximum mark. If electrolyte level falls
below the maximum mark it should be adjusted by adding the
electrolyte having specific gravity same as that is used for initial
filling.
At the end of charge, the electrolyte specific gravity shall be adjusted
to the value specified in the following table:
Description

NDP series
batteries

HDP series
batteries

SPV series
batteries

Starting rate of charging (% of

battery capacity)

10 %

12 %

10 %

Finishing rate of charging - Cells

/ batteries shall be charged at
this rate after their voltage
reached to 2.400 V/cell (% of
battery capacity)

5%

6%

5%

Charge voltage at the end of

charging - Indicates that the cell
/ battery is fully charged
Specific gravity of electrolyte at
the end of charging - Indicates
that the cell / battery is fully
charged

2.60 to 2.70 V/cell

1.200 +/- 0.005

Electrolyte temperature during

formation charge shall not
exceed

1.240 +/0.005

50C

Charge input (% of battery

capacity)
For cells / batteries made with
unformed plates
For cells / batteries made with
partially formed plates

550 %
minimum

660 %
minimum
300 % minimum

550 %
minimum

12
9.2

CATEGORISATION OF APPLICATIONS
Based on duty cycle applications are broadly classified into the
following 3 categories:

9.2.1 Float application

An application is said to be Float, when cells / batteries are
subjected to 3 to 5 discharges (of any DOD - Depth of discharge)
in a span of 1 year. OR Cells / batteries shall be on continuous
charge for a minimum period of 15 days between two successive
discharges (of any DOD - Depth of discharge).
9.2.2 Cyclic application
An application is said to be Cyclic, when cells / batteries are
subjected to more than 1 discharge (of any DOD - Depth of
discharge) in a span of 24 hrs.
9.2.3 Shallow cycling application
An application is said to be Shallow cycling, when cells / batteries
are subjected to prolonged discharges where discharge durations
will be in between 24 hrs to 120 hrs.
Generally these applications fall under Solar Photo Voltaic
applications. These applications also include the conditions like
deep discharging and partial state of charge operation since time
available for recharge is very short and at no point of time battery
attains 100 % state of charge during normal operation.
9.3

FRESHENING CHARGE
If cells/batteries are stored after completion of initial charging / after
certain usage period, freshening charge shall be given for every 3
months (while the cells / batteries are stored at 27 deg. C) as per
the procedure given below:
z For cells / batteries used with constant current chargers:
o Charge the cells / batteries at a current of 0.05 C for 6 hrs.

13
o Voltage of the cells on charge shall be reaching to 2.600 - 2.700
V at the end of this charging and specific gravities shall be 1.200
+/- 0.005 and 1.240 +/- 0.005 for NDP / HDP and SPV series
batteries respectively.
o If cell voltages & electrolyte specific gravities did not reach to
the values specified, continue to charge the battery at the same
current until voltage & s.g. values are achieved.
z For cells / batteries used with constant voltage chargers:
o Charge the cells / batteries at 2.400 V, 0.1 C current limit for 24
hrs.
o Electrolyte specific gravities of the cells / batteries shall be 1.200
+/- 0.005 and 1.240 +/- 0.005 for NDP / HDP and SPV series
batteries respectively.
o If electrolyte specific gravities did not reach to the values
specified, continue to charge the battery with the same voltage
until s.g. values are achieved.
9.4

NORMAL / ROUTINE CHARGING

Recharge the cells at 10 % current for NDP & SPV series cells and
12 % current for HDP series cell until cell voltage reaches to 2.400
V/cell. There after charge the cells at a current half of the initial
value i.e. 5 % for NDP / SPV series cells and 6 % for HDP series
cells until cell voltage reached to 2.600 - 2.700 V/cell.
Normal / routine charging method that is to be adopted for day- today usage is to be selected based on type of application. This can
be done either in Constant current mode or Constant voltage mode.
Since the batteries are of low maintenance type where there is a
provision for compensating the water lost during charging, these
cells / batteries can be charged both in Constant current mode and
Constant voltage / potential mode.
Prior to starting of charging of the battery, ensure that all the
connections (inter cell connections and out put connections) are
firm and tight. This is to avoid possible sparks and melting of
terminals.

14
9.4.1 Constant current charging
z Charger used for this purpose shall be of constant current type
having ripple content in output DC less than 3 % of RMS.
z The chargers should have provision for adjusting the charge
current.
z Charging should be done with the following currents:
o Cells / batteries of NDP series: Charge at a current of 10 % of
battery capacity until cell voltage reaches to 2.400 V/cell and
there after at a current of 5 % until cell voltage reached to 2.600
- 2.700 V/cell.
o Cells / batteries of HDP series: Charge at a current of 12 % of
battery capacity until cell voltage reaches to 2.400 V/cell and
there after at a current of 6 % until cell voltage reached to 2.600
- 2.700 V/cell.
o Cells / batteries of SPV series: Charge at a current of 5 % of
battery capacity until cell voltage reaches to 2.600 - 2.700 V/
cell.
Note: For all types of batteries, it shall be ensured that input on
recharge shall be minimum 110 % capacity drained in
previous discharge. Also, it is important to charge the battery
immediately after every discharge and maintain the battery
in fully charged condition.
9.4.2 Constant voltage / potential charging
z Charger used for this purpose shall be of constant voltage /
potential type having ripple content in output DC less than 3 %
of RMS.
z The chargers should have provision for adjusting both the charge
voltage and charge current.
z Charging should be done with the following voltage & current
settings:

15

9.5

Type of
application

Type of
charging
recommended

Float

Float

Cyclic

Shallow
cycling

Recommended charge settings

NDP series

HDP series

SPV series

2.15 - 2.20 V/
cell, 10 %
current

2.15 - 2.20 V/cell

& 12 % current

Not
applicable

Boost

2.40 V/cell,
10 to 20 %
current

2.40 V/cell,
12 to 24 %
current

Not
applicable

Boost

Not applicable

Not applicable

2.40 V/cell &

5 % current

EQUALIZING CHARGING

9.5.1 Need for giving equalizing charge

Variations among the cells (float voltages, on-load voltages and
electrolyte specific gravities) will increase over a period of time
while they are under usage. To safe guard the cells / batteries
from premature failure and improve system reliability equalizing
charge should be given at regular intervals when any of the
following is observed:
z When the difference between maximum and minimum float
voltage / on-load voltages (at the end of discharge) of individual
cell voltage is more than 0.100 V.
z When the difference between maximum and minimum value
of specific gravities of individual cells is higher than 0.020.
z At regular intervals based on type of application under which
batteries are used irrespective of float / on-load voltages and
electrolyte specific gravities of individual cells:
Type of application

Frequency of giving equalizing charge

Float

For every 6 months

Cyclic / Shallow discharge

For every 3 months

16
Note:
z In case of shallow discharge applications, equalizing charge
helps in raising the charge level of the battery (there by
minimizing the effect of PSOC on life of the battery) in addition
to minimizing cell-to-cell variations.
z If required, equalizing charge shall be given more frequently
(than the frequency given in the above table) if variation among
above-stated parameters of individual cells are crossing the
specified limits.
z Equalizing charge shall be started when battery is said to be in
fully charged condition as per the normal procedure.
9.5.2 Procedure for giving equalizing charge
9.5.2.1

For batteries used with constant current chargers:

a) NDP series:
z Charge @ 5 % current until voltages of all cells reaches to 2.600
to 2.700 V.
z While the battery is under charging, adjust the specific gravity
of electrolyte to 1.200 +/- 0.005 by adding distilled water.
z Minimum input that is to be given during equalizing charge shall
be 50 % of battery rated capacity.
b) HDP series:
z Charge @ 6 % current until voltages of all cells reaches to 2.600
to 2.700 V.
z While the battery is under charging, adjust the specific gravity
of electrolyte to 1.200 +/- 0.005 by adding distilled water.
z Minimum input that is to be given during equalizing charge shall
be 50 % of battery rated capacity
c) SPV series:
z Charge @ 5 % current until voltages of all cells reaches to 2.600
to 2.700 V.
z While the battery is under charging, adjust the specific gravity
of electrolyte to 1.240 +/- 0.005 by adding distilled water.
z Minimum input that is to be given during equalizing charge shall
be 50 % of battery rated capacity

17
9.5.2.2 For batteries used with constant voltage / potential chargers:
NDP / HDP series:
z Charge @ 2.500 V/cell, 10 % current for a minimum period of
16 hrs
SPV series:
z Charge @ 2.550 V/cell, 10 % current for a minimum period of
16 hrs
9.5.2.3

Conducting a full discharge there by recharge

If there is a provision for discharging all the cells, then this method
also can be employed.
z Discharge the cells @ 10 % current until all cells reaches to
1.850 V/cell. Bypass the cells those are reaching to 1.850 V
faster.
z Adjust the electrolyte specific gravity by adding distilled water
to 1.200 +/- 0.005 and 1.240 +/- 0.005 for NDP / HDP and SPV
series cells respectively while the cells are under charging with
low current i.e. in 2nd phase.
Note: Observe for variation in on-load voltages by conducting one
more test discharge @ 10 % load after giving equalling charge
with any of the above-detailed methods. If variations are still
exceeding the acceptable limits, then repeat the equalizing
charge for 2 more times. Even after 3 cycles (total), if
variations are not falling within the specified limits consult
HBL for guidance.
9.6

CHARGING AT MAINTENANCE YARDS

Use constant current battery charger having ripple less than 3 %.
The chargers should have provision to adjust the charging current.
Ensure that the all the connections (inter cell & out put cable) are
firm & tight prior to starting the charging of cell/ battery to avoid
sparks and melting of terminals.
Cells / batteries shall be charged fully following procedure detailed
in above sections. It is important to charge the battery immediately
after every discharge and maintain the battery in fully charged
condition.

18

10.0 PERFORMANCE OF BATTERIES

10.1 ACCEPTANCE TEST / CAPACITY TEST AT 10 HOUR RATE
z Freshening charge shall be given to the cells/batteries following
the procedure detailed in Section 9.3 prior to conducting
discharge test
z After standing on open circuit for 12 to 24 hours from the time of
completion of full charge, the cells / batteries are to be subjected
to capacity test at a constant discharge current of I=0.1 x C10
amperes (E.g.: A 200Ah cell shall be discharged at a current of
20 Amps). Measure and record the voltage, electrolyte sp.gr. &
temperature of each cell at hourly intervals from the beginning
of the discharge to end of discharge i.e. until cell voltage reached
to 1.85 V/cell.
z Calculate the capacity in Ah delivered by the battery by
multiplying the discharge duration obtained and discharge
current. Capacity obtained at test temperature shall be corrected
to 27 deg. C by using the following empirical formula:
C27 = CT x (1+ R x (27-T))
Where
CT = Obtained capacity at an operating temperature of T deg. C
C27 = Capacity corrected to 27 deg. C
R
= ROD factor - 0.43 for 10 hr discharge rate
T
= Electrolyte temperature in T deg. C
z It is recommended to conduct 2 to 3 charge / discharge cycles
before battery is put on operation.
z Battery shall be recharged as per the procedure detailed in
Section 9.5.2.3.
10.2

EFFECT OF TEMPERATURE
Lead acid battery is an electrochemical device and is sensitive to
temperature variations. Higher temperature accelerates chemical
activity and lower temperature slows it down, and hence cells/
batteries will give higher capacity and vice versa. Operating at
higher temperatures may give higher capacity momentarily but it
will lead to premature failures and there by shortens the life of the
battery. So, for optimum performance and life, it is recommended
to use the battery in environment having temperature close to 27C.

19
In general battery which is operated in a cool environment
(temperatures up to 10C) will last longer than the one which is
operated in hot environment. Low temperature operation will result
in low available output capacity. Temperatures below 10C will also
reduce the battery life.
Capacity that battery can deliver at different operating temperatures:
Capacity that battery can deliver varies with the operating
temperature. For estimating the battery capacity at temperatures
other than 27 C, following empirical formula to be used:
Capacity at T, CT = C27 / (1 + (R x (27-T) /100))
Where
CT = Capacity that battery can deliver at a temperature t C
C27 = Capacity corrected to 27 deg. C
R
= Rate of discharge (ROD) factor (Shall be chosen from the
table given below)
T
= Average room temperature in C
Rate of discharge (ROD) factors for different rates of discharges:
Discharge rate (Hrs)
ROD factor, R

120

72

Discharge rate (Hrs)

ROD factor, R

6
0.54

5
0.58

48
0.43
4
0.62

20

10

8
0.47

3
0.68

2
0.90

1
0.98

Note: The above empirical formula is valid for the operating

temperatures ranging from 15 to 55 C. Contact HBL for
information on battery capacity at temperatures less than 15.
z Temperature correction is not required for the charge voltage (if
used with constant voltage chargers) when operating at 27C. If
the operating temperature varies from 27C, charge voltage shall
be increased by 3 mV for every 10C fall in temperature and vice
versa.
Applying temperature correction to charge voltage will reduce the
gassing levels at higher temperatures there by lower the water loss
(topping up frequency will be low) by keeping the battery in fully
charged condition. For further details related to temperature
correction factors, contact our nearest branch office.
z Exercise caution while operating or storing batteries at very low
temperatures as there is a possibility of electrolyte freezing.
z Temperature compensation will improve the battery service life
when strictly followed.

20
10.2 MONITORING OF BATTERIES
10.2.1

BATTERY MAINTENANCE

z Inspection & record

The cells/batteries should not be subjected to over charge and at
the same time, it should be ensured that they receive full charge
after every discharge. Otherwise, battery would not be a reliable
source of power in case of emergency.
Batteries shall be monitored at regular intervals (monthly, quarterly,
half yearly and annually) in addition to any other attention that the
user may desire to give.
Conducting routine maintenance checks as per the schedule
planned and maintaining the records of both battery and its charging
equipment would help in detecting abnormalities if any so that
necessary corrective / preventive measures can be taken in time
to avoid system failure.
Micro porous vent plugs and level indicators shall always be kept
in place with tight fitting while in service operation to avoid water
loss through evaporation.
z Monthly inspection
o Select the pilot cells (one cell for every 6 cells) in a set, which
are considered to represent the characteristics of other cells in
the system. Change the pilot cells every month on rotation basis,
so that all the cells are covered in a year.
o Check the integrity of connections (inter cell connectors and
out put cables). Also, all connections shall be cleaned if dust
accumulation is observed.
o Check for any corroded connectors, if observed clean them
thoroughly and apply petroleum gelly on terminal bolts. In worst
case, replace the corroded components.

21
o Record open circuit voltage for pilot cells. Verify state of charge
(SOC) with voltage of pilot cells and take necessary action if
SOC is observed to be low.
o Measure and record the on-load voltages of all the cells (after a
minimum period of 15 min from the time battery is put on
discharge) while the battery is loaded / discharged with site load.
o Check the voltage & current settings on charger, correct if any
deviations are observed.
o Check for any dust accumulation on cell cover, vent plug if
observed, clean it thoroughly.
o Check the tightness / firmness of vent plug.
o Check for any broken container or cover. Remove and replace
with good one, as it will damage the battery stand.
z Half-yearly Inspection
o Verify the monthly inspection reports.
o Check the level of electrolyte of each cell in the system. If any
cell showing the float level above RED MARK or less, top up
with distilled water up to green mark. Record the quantity of
water topped up to each cell.
o Check the condition of vent plug. Replace if it is broken.
o Check for the proper functioning and accuracy of measuring
instruments (Ammeter and Voltmeter). Replace with calibrated
instruments if not satisfactory.
o Check the open circuit voltage & electrolyte specific gravity of
each cell and ascertain the state of charge of the battery referring
the tables / graphs given below.
o Give equalizing charge as detailed above.
Note: For adjusting the electrolyte levels, distilled water shall only
be added to the cells/batteries but not the normal water /
packaged drinking water.

22
z Annual Inspection
o Remove the cells from the battery stands and bring them to
battery shop for attention.
o Clean the acid traces if any on out side surface of the cells after
fitting the plugs.
o Follow special maintenance instructions for revival of cells /
batteries suffering from undercharging due to frequent deep
discharges, improper charging and not giving equalizing charge
as and when required.
o Test for capacity at 10 hr discharge rate. If capacity of any cell/
battery is observed to be less than 80 % of rated value, then
subject them to revival exercise. Even after revival, if capacity
is observed to be less than 80% of the rated value, replace them.
o Recharge the battery following the applicable procedure detailed
in Section 9.5.2.3
o Clean all the ventplugs in warm DI water to remove the dust
accumulated on ventplugs.
z Inspection
If battery failure or other difficulty is reported, conduct the following
checks and tests in sequence:
o Measure the total voltage of battery on open circuit and under
load. If it is normal, then problem must be with some other
equipment.
o Check all battery connections to ensure that they are clean and
tight.
o Measure and record the voltage of all cells in the system. If,
voltage of all the cells is low, it indicates that the battery is either
deep discharged or it is not receiving sufficient charge due to
the problems with charging equipment. In either cases, recharge
the battery with alternative power plant / charger without any
delay. Locate the cause of deep discharge / undercharge and
take necessary corrective & preventive measures.

23
o If voltage of one or more cells is observed to be relatively low,
check for electrolyte level and specific gravity of the same and
adjust if the values are deviating from normal range. Give
equalizing charge following the procedure detailed in Section
9.5 If cells did not improve even after giving equalizing charge,
then replace them.
o The Performance of the batteries shall be monitored during
operation at regular intervals for various parameters detailed
above in order to detect and correct abnormalities, if any.
o Maintain records of all parameters (float voltages, on-load
voltages, electrolyte s.g., etc.) monitored at various intervals
using the service record formats, and send a copy of the same
to M/s HBL for monitoring the performance of the battery. Failure
to maintain service record will invalidate the warranty of the
battery.
Note: Instruments used for testing shall be duly calibrated and shall
have the accuracy & least count specified below:
Instrument

Accuracy

Least count

Digital volt meter / Multimeter

0.5 %

1 mV

Digital Ammeter / Clamp meter

1.0 %

0.1 A

1 deg. C

1 deg. C

0.01 points

0.01

Temperature indicator / Thermometer

Hydrometer

10.2.2

State of charge (SOC) of the battery

The state of charge (SOC) for low maintenance lead acid batteries
can be predicted roughly through electrolytes specific gravity
measurements using the following table
State of charge
(SOC)

Electrolyte Specific gravity

NDP series

HDP series

SPV series

100 %

1.200

1.240

75 %

1.193

1.210

50 %

1.182

1.170

25 %

1.160

1.130

24

11.0 DO's AND DON'TS

11.1 DO'S
z Read this manual carefully before putting the battery on usage
/ working on batteries.
z Unload the batteries carefully and place them as recommended.
z Store the batteries in a cool and dry location.
z When the battery is not in use, keep it in a cool place.
z Monitor the charging voltages of the power plant / charger at
regular intervals.
z Check the tightness of all electrical connections at monthly
intervals.
z After discharge, recharge the battery without much delay (delay
should not be more than 3 hrs).
z Maintain service records, which helps in trending / analysing
the battery health while it is under usage.
z Clean the dust and dirt at vent plug cover, terminals and
surrounding area with clean and dry cotton / cloth.
z Use only flexible copper cables of required size from power plant
/ charger for charging the battery.
z Ensure that connections are made with correct polarity while
connecting the battery on to charging. If charged with reverse
connections it acts as a short circuit for the charger and also
cells/batteries will suffer from irreversible damage.
z Contact HBL for further help and guidance.

25
11.2

DON'TS
z Never place the cells nearer to fire.
z Do not connect or disconnect any cell without switching off the
load & charger.
z Do not expose the battery to (hostile) hot environment.
z Do not store the Charged batteries for longer periods without
giving freshening charge at regular intervals.
z Do not short the terminals of the cells / battery.
z Do not over-tighten the nuts/bolts while giving connections.
z Do not mix batteries of different types or makes.
z Do not mix low maintenance lead acid cells with VRLA cells or
vice versa.
z Do not make intermediate / tap connections from battery.
z Do not charge two or more sets of batteries (of same capacities
/ different capacities / different types / makes) connected in
parallel.
z Do not connect extra load (over and above specified) on to the
battery.
z Never discharge cells below 1.85 V/cell.
z Do not add acid during for adjusting the electrolyte level. Only
water is lost during battery operation, so add only distilled water
to adjust the electrolyte level.

12.0 PRODUCT WARRANTY

12.1 WARRANTY
HBL gives a warranty to the user that the Low maintenance lead
acid Batteries are free from defects in material and workmanship
for a period of 12 months from date of installation or 18 months
from the date of shipment, whichever is earlier. This warranty is
applicable for the cased where battery is operated at 10 hr discharge
rate, Depth of discharge < 80 %, 27 deg. C and charged as per
manufacturer's recommendations. Warranty period will vary based
on operating conditions of the application (Operating temperature,
Depth of discharge, Rate of discharge, Available charge settings
in power plant). Consult HBL for warranty period specific to
application.

26
HBL must be notified immediately upon detection of any defects
and HBL has the authority to inspect any questionable sites. If HBL
determines the batteries to be defective due to material or
workmanship, it will repair or replace them at its own option.
12.2 EXCLUSIONS AND LIMITATIONS
z Warranty does not cover physical damage due to the acts of
nature or man, which stress the battery beyond design limits
and exert undesirable influence, which enhance normal wear
and tear.
z Warranty will cease if the units are opened or tampered with, or
an attempt is made to repair the battery by any person other
than the manufacturer's authorised representative.
z HBL will not be responsible for any work accomplished or
expenses incurred except with expressed written consent from
HBL.
z HBL shall not be liable for indirect, incidental or consequential
damages arising out of the sale or relating to the use of this
product, and the purchaser assumes responsible for all personal
injury and property damage resulted during handling, possession
or use of the product.
z In no event shall the liability of HBL, for any and all claims;
including claims of breech of warranty or negligence, exceed
the purchase price of the product.
z The above warranty is in lieu of all other remedies, including
actions. For contract or negligence (incomplete sentence). All
other warranties expressed or implied including but not limited
to the warranties of merchantability and fitness for a particular
purpose are hereby excluded.
z User shall not return the batteries to HBL without prior
information.

27
12.3 WARRANTY CONDITIONS
z The Low Maintenance Lead Acid Batteries are warranted against
material & manufacturing defects for a period of 12 months from
the date of installation or 18 months from the date of dispatch,
whichever is earlier. This warranty limits the purchaser remedy
for the repair or replacement of a defective battery or parts
thereof due to manufacturing defects. The right to determine
whether a battery or cell needs to be repaired / replaced or not
lies with the manufacturer.
z Warranty period will vary based on operating conditions of the
application (Operating temperature, Depth of discharge, Rate
of discharge, Available charge settings in power plant). Consult
HBL for warranty period specific to application.
z Warranty is null and void for those charged batteries which have
been stored for more than 6 months without giving a freshening
charge or when the cell / battery have been tampered with.
z Warranty claims will not be entertained, if the operating
instructions are not strictly adhered to.
z Warranty will not be entertained, if an attempt is made to repair
the battery by any person other than the HBL authorized
representative.
z Warranty is applicable only for those batteries for which the
Service records are maintained as per the guidelines given in
this booklet.
z Warranty will cease for the batteries or cells damaged during
transit unless the local representatives of manufacturer to
informed within 7 days from the date of receipt of the damaged
consignment.
z Warranty claims will not be entertained if transit damages are
notified after storage period.
z Litigation arising out of any transaction with the company is
subjected solely to Hyderabad jurisdiction.

28

13.0 MAINTENANCE
13.1 CHECK LIST
Impact if not followed /
maintained
Accumulation of dust & Cell / Battery surface shall be Self-discharge will be higher in case
acid spillages on Cell / kept clean, dry and tidy
battery is under storage. Acts as a
Battery surface
path for leakage voltage there by
chances of getting electrical shock
in high voltage systems
Check

Requirement

Condition of container There shall be no cracks in Having cracks in container / sealing

and sealing compound cell / battery container / compound may lead to acid
sealing compound.
leakages / spillage, which in turn
results in performance degradation
and untidy environment.
Integrity
of
all
connections in the
battery system and
cleanliness of the
terminals
Venting holes of the vent
plugs

All connections (inter cell and

out put) shall tight and firm.
Terminals shall be cleaned
and coated with petroleum
gelly.
Shall be clean and there shall
be no blockings

Presence of loose connections will

lead to sparking. Not cleaning the
terminals / applying petroleum gelly
may lead to corrosion.
Deterioration of cell condition and in
worst case it may lead to cell /
battery explosion

13.2 GUIDE LINES FOR TOPPING UP WITH DI / DM WATER DURING

SERVICE OPERATION
HBL's low maintenance lead acid batteries require periodic topping
up on a reduced scale compared to conventional lead acid batteries.
Each cell of the battery is provided with electrolyte level indicators,
which serves as a visual aid for knowing the level of electrolyte
inside the cell. Markings are provided on top of transparent tube
with Green and Red to indicate the electrolyte level.
The float travels inside the transparent tube showing the level of
electrolyte. Micro porous vent plugs are provided in each cell to
minimize water loss, which allows only gasses to escape.
Lead acid battery looses water due to over charging (which drives
the battery into heavy gassing mode due higher electrolysis) and
through evaporation when battery is operated at higher
temperatures.

29
The loss of water in HBL's low maintenance lead battery was
ascertained through extensive tests. Results indicate that topping
up is required ONCE IN > 6 MONTHS while it is continuously over
charged @ 2.400 V/cell and 50 deg. C. In actual operating
conditions, such continuous over charging will not be present (the
batteries under goes charge / discharge cycles) as and hence the
topping up frequency will be further low.
Above explanation on reasons for water loss & how it is being
reduced in our design may not be required for the user. We shall
detail on when & how to top up.
HBL recommends to top up with distilled water once in 6 months or
whenever the float guide reaches close to RED MARK in order to
avoid to increase in specific gravity of electrolyte due to evaporation
of water, which will affect the life of the battery.
Prior to topping up with distilled water, charge status of cells shall
be verified with by voltage and specific gravity measurements.
Measure and record the voltage & s.g. values prior to topping up.
Topping up is to be done while the battery is in fully charged
condition. Indication for battery being in fully charged condition is
as follows:
z For batteries used with constant current chargers: Cell voltage
on charge shall be in the range of 2.600 - 2.700 V/cell.
z For batteries used with constant voltage chargers: Current drawn
by the battery shall be stabilised at low current and variation in
3 hourly readings shall be less than 5 %.
While the battery is in fully charged condition, electrolyte specific
gravity will reach to the maximum possible value and under this
condition add distilled water until the float guide in level indicator
touches the GEEN / MAXIMUM mark.
After topping up with distilled water, cells shall be overcharged for
minimum 6 hrs to enable proper mixing of electrolyte through
gassing there after electrolyte specific gravity shall be measured
and recorded. Measured s.g. Shall be in the range specified for
each type of battery.

30
13.3 SYMPTOMS OF BATTERY FAILURE, PROBABLE CAUSES
AND REMEDIES
Symptom

Probable causes

Corrective / Preventive
actions

Electrolyte specific gravity is - Float charge voltage set is high - Adjust the charge voltage to
increasing in less time span while - Error in measuring instruments the specified value.
the batteries are on float charge
(Voltmeter)
- Correct the voltmeter's error if
any
Progressive decline in value of - Float charge voltage set is low - Adjust the charge voltage to
specific gravity while the battery is - Error in measuring instruments the specified value.
on float charge
(Voltmeter)
- Correct the voltmeter's error if
any
- Cell / battery surface shall be
cleaned with (Na2Co3) washing
soda thoroughly to eliminate
leakage paths.
Rapid fall in on-load voltage of cell - Loose connection or corroded - Make all connections firm and
/ battery during discharge
terminals must be present which tight
causes higher voltage drop
- Clean corroded terminal parts
with dilute alkaline solution and
water there after with dry cloth
and apply petroleum jelly
Cell getting discharged

- Leakage paths must be present

due to dust accumulation /
electrolyte spillage or leakage.

- If cracks are present on battery

container where leakage cannot
be arrested, replace the
container / battery
- Adjust the charge voltage to
the specified value and correct
voltmeter's error if any
Low open circuit voltage and low - Cell / battery must be suffering - Conduct the revival activity
capacity in spite of giving full from undercharging
following the guidelines detailed
charge, Low electrolyte specific - Cell / battery must be suffering in Section 14.0
gravity
from internal shorts
If problem continue to exist
even after conducting revival
activity replace the cell.
Electrolyte level is falling below the - Leakage of electrolyte through
minimum level within a short period cracked container
- Higher water loss due to
charging at higher float voltage

Excessive gassing

- Cells / batteries must be on

charging at higher voltage that
the specified.
- Sulphation due to low
electrolyte level / frequent deep
discharges / under
- Topping up with diluted
sulphuric acid to adjust the
electrolyte level.

- Adjust the charge voltage to

the specified value and correct
voltmeter's error if any
- Adjust the electrolyte level and
conduct revival activity to solve
the sulphation problem.
- To adjust the electrolyte level,
topping up shall be done with
distilled water but not diluted
sulphuric acid.

Electrolyte is overflowing from the - Electrolyte level must be above - Adjust the electrolyte level
cell / battery
the maximum level
such that it doesn't go above
maximum mark
Reverse polarity in cells

- Cell / battery must have grown

weaker because of not giving
equalizing charge at regular
intervals.
- Cells / batteries must be
subjected to frequent deep
discharges.

- Equalizing charge shall be

given at regular intervals
following the guidelines given in
Section 9.5
- Conduct the revival activity
following the guidelines detailed
in Section 14.0. If there is no
improvement, replace the cell /
battery.

31

14.0 SPECIAL MAINTENANCE INSTRUCTIONS

14.1 REVIVING CELLS WITH LOW VOLTAGE & LOW SPECIFIC
GRAVITY
z One among the reasons for low voltage and low specific gravity
is improper and initial charging. User shall follow the instructions
given by the supplier for initial filling of electrolyte and charging.
Even after complete duration of charge, if any cell voltage is
showing less than 2.550 V, such cells should not be put into
service and it shall be informed to the supplier.
z During service, if cell open circuit voltage is found less than
1.980 V, then discharge the cell at C10 rate till end cell voltage
of 1.850 V (for NDP / HDP / SPV series batteries) / 1.850 V (for
SPV series batteries) and then recharge following the guidelines
given in Section 9.5.2.3.
z After completion of normal charging, equalizing charge shall be
given following the guidelines given in Section 9.5
z If the cell does not give rated capacity in 10 hr discharge test, it
shall be repeated for one more cycle.
z It shall be ensured that specific gravity of electrolyte falls in to
the normal range at the end of charging. If deviations are
observed it shall be adjusted by adding distilled water.
z In spite of completing the above exercise, if voltage of few cells
is still low, then they shall be boost charged with cell boosters.
If improvement is not observed, they shall be replaced.
z If cells are stored for more than one month in fully charged
condition then freshening charge shall be given following the
procedure given in Section 9.3.
14.2

REVIVING A DEAD CELL

This happens when plates are heavily sulphated. It may be due to
continuous undercharging or storing the cells in discharged
condition for prolonged periods.
z Drain out the electrolyte from the cell.
z Fill the cell/battery with distilled water and allow the cells /
batteries to be under rest for 2 to 4 hours.

32
z Charge the cell with a current 5 % of rated capacity until cell
voltage reaches to 2.300 - 2.400 V/cell. Please be noted that,
voltage will not increase further as the electrolyte is weak (more
diluted / less specific gravity).
z Dump the electrolyte completely after completion of above
charging and fill with the fresh electrolyte having gravity specific
to each type of battery pertaining to 100 % state of charge (for
NDP / HDP series cells / batteries - 1.200 +/- 0.005 and for SPV
series cells / batteries - 1.240 +/- 0.005).
z Charge the battery following the procedure detailed in Section
9.5.2 Check the specific gravity of electrolyte at the end of
charging and adjust it to the value specified above (if SG is low
add the electrolyte of 1.400 specific gravity and if it is high add
distilled water) and continue charging for two hours to enable
proper mixing of electrolyte.
z Conduct C10 discharge, if cell does not give desired capacity
(minimum capacity that battery shall deliver to put into service
is 80 % of rated value) cell/battery shall be discarded.
14.3 REVIVAL OF A CELL THAT HAS ATTAINED REVERSE
POLARITY
This happens when the battery is discharged deeply below ZERO
volts. If such deep discharge occurs repeatedly / number of times
battery will attain reverse polarity (show negative voltage). These
batteries should be taken out for revival action immediately. Any
delay will reduce the possibility of revival.
Following remedial actions are recommended for revival of cells /
batteries suffering from reverse polarity:
z Drain out the electrolyte from the cell/battery.
z Rinse the cell/battery with distilled water for 3 to 5 times and
shall be dried.
z Fill the cell with distilled water and allow the cells / batteries to
be under rest for 2 to 4 hours.
z Follow the procedure detailed in the above section / Section
14.2.
z Consult HBL for clarifications & guidance.

33

SPECIFIC GRAVITY CORRECTION CHART

Specific Gravity Correction factors:
For every 1C above 27C subtract 0.0007 from the value recorded
in the hydrometer. For every 1C below 27C, add 0.0007 from the
value recorded in the hydrometer. The following is an example
how the correction factor is applied.
Temperature
of acid
37C
27C
17C

Hydrometer
Reading
1.25
1.25
1.25

Correction
Factor
-0.007
0.0
+0.007

ACID MIXING CHART

When Mixing By Volume
When mixing By Volume
(Litre) Using 1.800 Acid
(Litre) Using 1.400 Acid
Distilled Water Required to Distilled Water Required
one part acid
to one part acid
0.45
2.80
0.53
2.90
0.60
3.00
0.64
3.09
0.67
3.17
0.75
3.35
0.82
3.55
3.68
0.86
0.90
3.80
1.10
4.30
5.00
1.41

Corrected
Sp.Gr
1.243
1.250
1.257

Desired Specific
gravity at 27C
1.280
1.270
1.260
1.255
1.250
1.240
1.230
1.224
1.220
1.200
1.180

Electrolyte Preparation:
Battery Grade sulphuric acid is usually available in 1.800 or 1.400
Sp.gr. concentration. To change the sp.gr. to another value , it is
necessary to mix it slowly with distilled water, to obtain the desired
specific gravity.
Caution:
1. Store sulphuric acid only in plastic or lead containers.
2. Add acid slowly to DI water while mixing, especially when using
high gravity acid. Never add water to acid.
3. Always wear goggles, rubber gloves and apron while handling
acid. Be extremely not to spill or splash acid.

34

CUSTOMER SERVICE CENTRES

Sl.
No.

Branch

Address

Tel. No.

Fax No.

Remarks

Banglore

HBL Power Systems Ltd.,

No.44, Central Street, Shivaji
nagar, Banglore - 560 001.

080-41130303

080-41130306

Service

Bhopal

HBL Power Systems Ltd.,

E-7/30, Ashoka Society, Arera
Colony, Bhopal-462016 (M.P.)

09329787676

Service

Chennai

044-42970300
(10 Lines),
32969870

044-4290333

Service

9444985576

Service

0484-2334007,
9388694890

Service

4 Coimbatore

Cochin

Delhi-1

Gujarat

Hubli

Hyderabad

10

Jaipur

11

Kolkatta

12

Lucknow

13

Madurai

14

Mumbai

15

Punjab

16

Pune

HBL Power Systems Ltd.,

Survey No. New No.21, Old
No.7/2, Srivas Building, Kellys
Road, Kilpauk, Chennai-10
HBL Power Systems Ltd.,
Indiranagar, 1st street,
Mujundaturam road,
Coimbatore - 641 036.
HBL Power Systems Ltd.,
Pallath House, Naroth Road,
Thammanam (Post),
Palarivattam, Cochin.
HBL Power Systems Ltd.,
Plot No.248, Patpergunj
Industrial area, Delhi-110 092
HBL Power Systems Ltd.,
B-192, GIDC, Electronic Zone,
Sector-25, Gandhinagar,
Gujarat - 382 025.
HBL Power Systems Ltd.,
No.141, Chalukya Nagar, Gadag
Rd, Hubli - 580 023.

011-22161210,
011-42141129
22160062
982451488

Service

9900138296

Service

HBL Power Systems Ltd.,

040-32921532,
Block - A, Kubera Towers,
040-27795419
32464972
Thirumal Gherry, Secunderabad.
HBL Power Systems Ltd.,
Nindar mod, Sikar road,
Harmada, Jaipur - 302 013.
(Rajasthan)

Service

0141-3223455,
09314884881

HBL Power Systems Ltd.,

BD-79, Sector 1, Salt Lake City, 033-23218060
Kolkatta-64.
HBL Power Systems Ltd.,
0522-3257206,
9/32, Suryodaya Colony,
0522-3017509
Ranapratap marg,
09335912383
Lucknow-226 001.
HBL Power Systems Ltd.,
Vellai Pillaiar, Koil street, Near
9444985567
Subhiksha stores, S.S.Colony,
Madurai - 625 010.
HBL Power Systems Ltd.,
Aditi, F2-A5, 3rd Floor, Sector-9, 022-27895576
022-27895576
Near Shabri Hotel, Vashi,
Mumbai-400 703.
HBL Power Systems Ltd.,
C-49, (Opp.Ranbaxy), Phase-III, 0176-232239,
Industrial Area, Mohali, Punjab - 09316875903
160 059.
HBL Power Systems Ltd.,
Akshay park, Shop no.39, 40, Near
Santosh mangal, Opp. Seva vikas 9372495970
karyalay
bank ltd, Thergaon, Pune-411 033.

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