INSTRUCTIONS FOR

THE OPERATION AND MAINTENANCE

OF

OpzS RANGE OF BATTERIES

USED WITH

FLOATING AND TRICKLE CHARGE SYSTEM

GENERAL :

In order to ensure safety, it is essential to operate and maintain your batteries in

accordance with the recommendations in this booklet.

a) ACID : Batteries contain dilute sulphuric acid which is poisonous and corrosive. It
can cause burns on contact with skin and eyes. If acid is split on skin or clothing,
wash plenty of clean water. If acid gets in to the eyes wash well with plenty of
clean water and get IMMEDIATE MEDICAL ATTENTION.

b) GASES : Batteries can give off explosive gases. Keep sparks, flames and lighted
cigarettes away from battery and battery room. Ensure connections are tight before
switching on, using only insulated tools. Areas where batteries are kept or charged
must be adequately ventilated.

c) ELECTRICITY : Use only insulated tools to make connections to a battery. Check

the circuit to ensure it is safe before making a connection to the battery. Before
working on a battery, always remove personal metal effects, such as rings, watches,
bracelets, necklaces, etc.

ALWAYS PROTECT THE EYES.

d) ERECTION : Erection and commissioning of batteries to be done in accordance

with separate instructions provided by manufacturer.
FLOATING BATTERY SYSTEMS

In a floating battery installation the charger, battery and load are connected in parallel.
The charger supplies the load current continuously whilst the battery remains in a charged
condition, immediately capable of supplying the load should the main supply be
interrupted.

1. CONDENSED INSTRUCTIONS

Top up all cells regularly with distilled or deionised water. Keep the electrolyte
level between the red and green mark, preferably near the green mark, etched on the
transparent level indicator.

If, before topping-up, the electrolyte level had fallen below the red mark, it is
advisable to give the battery a charge for approximately ½ hour above 2.3 volts per
cell after addition of battery grade distilled water in order to mix the electrolyte.
Keep battery and surroundings clean and dry.

Ensure bolted connections are tight. Keep connectors, pillars and bolted
connections covered with petroleum jelly for protection against corrosion.

Take every precaution to avoid risk of explosion of gases particularly during

charge. Never smoke or use a naked flame near the battery, or in the battery room
or take any action which could cause an electric spark.

Ensure that charging equipment maintains the battery at the correct voltage.

Examine all cells at regular intervals. Action should be taken to restore any “out of
step” cells to a fully charged condition.

The room in which the battery is housed should be well ventilated and its
temperature as moderate as the climate will allow. The temperature of electrolyte
should preferably never exceed 380C
2. FLOATING

The method of operation known as “floating” means that the charger, the battery
and the load are connected in parallel. The battery should be held constant at a
voltage between 2.15 to 2.20 volts per cell, so that the battery will normally be
maintained in a fully charged condition. The voltage to be maintained based on the
ambient temperature as detailed in Table – I.

Temperature Float Voltage

<5 deg. C 2.20±0.02 vpc
0 0
20 C – 35 C 2.18±0.02 vpc
360C – 450C 2.15±0.02vpc

TABLE - I

The charger on a floating system should have a current rating sufficiently high to
ensure that the battery does not become discharged during prolonged periods of
operation. The current rating of the charger should be higher than the normal
continuous loads of the system, so that the battery only supplies the short duration
peak loads when the current required is greater than the charger output.

The voltage output of the charger may be regulated either automatically, or

manually. The automatic type of constant voltage charger will maintain the pre-set
steady voltage indefinitely, if used within its rated output. With the manual type of
charger, however, care should be taken to keep the voltage level correct at all times,
particularly if loads vary appreciably, by adjustment of the voltage control.
3. BOOST CHARGING

The battery should be recharged as soon as possible after any discharge, amounting
to more than 5 to 10% of the rated capacity of the cells. A reference to the specific
gravity of electrolyte in the pilot cell will indicate when a charge should be given.
Should the fall in gravity of the pilot cell from the normal fully charged value, be
greater than the allowable specific gravity drop, then the battery should receive a
boost charge.

Operate the charger in accordance with the separate charger instruction, so as to

supply a charge current to the battery. The initial “starting rate” charging current
can be any value up to two times the “finishing rate” of charge, as given in the
Appendix. The voltage of the battery will rise as the battery becomes charged.
When the battery voltage reaches a value equivalent to 2.36 volts per cell, the
charge current should be limited to a maximum of the “finishing rate” of charge.

Where automatically regulated charges are employed, the charge current may not be
under manual control, but the current output of such charges should not greatly
exceed the finishing rate of charge, when the cells are gassing.

Charging should be continued, taking specific gravity and voltage readings on the
pilot cell, at half hourly intervals, until the readings become sensibly constant over a
period of 2 hour.

After the charging is over, the specific gravity of electrolyte has to be adjusted, if
required, to a value indicated by the manufacturer by addition of demineralised
water only. Use well calibrated hydrometer for the purpose of specific gravity
measurement with a tolerance of +/- 0.005 points. Never use acid for level
adjustment of cells.

The type of charger and the controls provided on it, will determine the procedure to
be carried out in order to charge the battery. The manufacturer’s charger
instructions should be referred to if in doubt.
4. PILOT CELL

Select one cell of the battery as a ‘pilot cell. For batteries containing more than 60
cells, select one pilot cell for each 60 cells.

Any variations in specific gravity of the electrolyte in the ‘pilot’ cell(s) will be
indicative of the state of charge of the whole battery.

Keep the electrolyte level between the red and green mark, preferably near the
green mark, etched on the transparent level indicator by adding distilled or
deionised water when required. After topping up, it is preferable to give the battery
a charge for approximately ½ hour, above 2.3 volts per cell. This will mix the
electrolyte and prevent water from stratifying at the upper level.

GENERAL INFORMATION

1. Specific gravity

The specific gravity of the electrolyte in fully charged cells should be

1.240+/-0.005 at 270 C. During the course of years there may be a slight fall
in the maximum specific gravity values obtainable at end of charge, but acid
should never be added except on the recommendations of the manufacturer.

2. Topping up

Due to evaporation, and gassing on charge, water is lost from the electrolyte,
and the level gradually falls. Water must be added at intervals to bring the
electrolyte to the correct level. Do not allow the levels to fall below the red
mark. The water used for this topping-up operation must be pure and should
be demineralised and conforming to IS 1069

Never use metal vessels for storing or dispensing the topping-up water.
 Water should preferably be added below the surface of the electrolyte, by use
of a rubber syringe or plastic funnel. This helps to mix the water with the
electrolyte. It will also help to assist mixing by having the battery on charge,
with all cells gassing, either during, or soon after topping-up.

3. Preservation

Keep the battery and surrounding clean and dry. Wipe down the cells with a
clean soft cloth dampened with clean water, if necessary, a small amount of
mild detergent may be added to the cleaning water to remove any greasy
film.

Ensure bolted connections are tight. Keep connectors, pillars and bolted
connections covered with petroleum jelly for protection against corrosion.

Should any corrosion of the connectors occur because of spilt acid etc.
carefully remove corrosion products, thoroughly clean and neutralize with
alkali solution or dilute ammonia.

Dry the affected parts and liberally coat with petroleum jelly to protect from
further corrosion. Care should be taken to ensure that the neutralizing
solution does not enter the cell.

4. Temperature correction

The specific gravity of the electrolyte varies with temperature. Any reading
observed on the hydrometer should therefore be corrected as follows:

For every 100 , above 150 C, add 7 point (0.007 specific gravity) to the
specific gravity as read on the hydrometer.

Similarly, for each 100 C, below 150 C, subtract 7 point (0.007 specific
gravity) as read on the hydrometer.
MAINTENANCE SCHEDULE

The maintenance schedule given here is divided in daily, weekly, monthly and yearly
maintenance. The actions to be taken, checks and recording required are given herewith.

A. DAILY MAINTENANCE

A daily general maintenance should include a check and record of the following :

1. Overall float voltage measured at the battery terminals

2. Charger output current and voltage

3. Specific gravity, voltage and temperature of pilot cells.

B. WEEKLY MAINTENANCE

A weekly maintenance should include all the items mentioned in “daily

maintenance” and the following :

1. Check electrolyte level of all cells and if required, top-up with battery grade
water conforming to IS 1069. Never use metal vessels for topping up
because of the risk of electrolyte continuation and accidental short circuit.

2. Visually check the conditions of each cell and battery bank. If abnormal or
very high amount of sulphation on the terminals or connectors are observed,
take immediate action in removing them.

3. Visually check the cleanliness of battery, battery stands and battery room
area for accessibility, cell integrity and acid leakage.
C. MONTHLY MAINTENANCE

A monthly maintenance shall include all checks listed under “daily” and “weekly”
maintenance schedule and also the following :

1. Check and record specific gravity, voltage and temperature of all cells in the
battery bank.

2. Adjustment of specific gravity by addition of battery grade water is to be

done only after charging and under skilled supervision (Never use acid for
this purpose unless specifically suggested by manufacturer).

3. After adjustment of specific gravity, charge the battery at a voltage around

2.4 volts per cell for a period of 2 hours for mixing of the electrolyte
properly.

D. QUARTERLY MAINTENANCE

A quarterly maintenance shall include all checks listed under “daily”, “weekly” and
“monthly” maintenance schedule and also the following :

1. Check and record specific gravity, voltage and temperature of all cells in the
battery bank.

2. If the specific gravity of most of the cells are found to be lagging by an

average of 10 to 15 points, the battery bank would call for an equalizing
charge at a current equivalent to 3% - 5% of its rated value for 6 – 10 hours
to restore the state of charge to full.
 3. The temperature of the electrolyte normally is higher than the ambient. But
for a bank, unless it has undergone a discharge within previous 24 hours, the
electrolyte temperature should lie within 3 – 5 deg. C higher than the
corresponding ambient temperature. In case of a deviation from this range,
the charger needs to be checked for its quality of power output in terms of the
ripple contents in the charging voltage and current. Corrective action should
be immediately taken to avoid any deterioration in the battery bank due to
this anomaly.

E. HALF YEARLY MAINTENANCE

A half yearly maintenance shall include all checks listed under “daily”, “weekly”,
“monthly” and “quarterly” maintenance schedule and also the following :

1. Remove all corrosion product and clean connector thoroughly. Use enough
amount of petroleum jelly on the connectors to prevent farther corrosion and
put back shrouds in place.

2. Check the tightness of fasteners on inter-cell, inter-row and inter-tier

connections to prescribed torque values as suggested by manufacturer. If
required, tighten the connections to the required torque value .

F. YEARLY MAINTENANCE

A yearly maintenance should include all items listed under ‘daily’, ‘weekly’ and
‘monthly’ maintenance schedule and also the following :

1. Discharge the battery at C10 current for 10 hours followed by a constant

current recharge. The charging to start at the “starting rate” as mentioned in
the product catalogue for the respective size till the cell voltage reached 2.36
volts per cell followed by charging at “finishing rate” pertaining to the
specific size of the battery as mentioned in manufacturer’s catalogue. The
charging to be stopped when the cell voltage and specific gravity readings are
constant for four consecutive half hourly readings.
2. The expected end-of-charge voltage is of the order of 2.7 – 2.75 volts per
cell. During charging it has to be ensured that a minimum Ah input of 125%
of the previous discharged Ah is administered to the battery. The
temperature during charging should not increase beyond 450 C. In such
cases, the charging to be stopped and the cells to be allowed to cool down till
400 C when the charging can be resumed. The timings are to be noted so that
the duration of charge can be compensated accordingly to ensure that the
minimum Ah input requirement is fulfilled.

3. After the charging is over, gravity and level adjustments are to be carried out
after a rest of 4 hour.

4. The battery bank, then, is to be given an equalisation charge at a current

equivalent to 3% - 5% of rated C10 capacity for 12-24 hrs.

5. The battery bank can be given back to the system after the equalising charge
is over.