Contents

1. Safety Information & Instructions on the product.

2. Principle of operation for lead acid battery.
3. Preparing a battery for service.
4. Warranty Informations.
Chapter 1:

1. Safety information about the product:

Caution:

This battery system generates highly explosive hydrogen which remains inside the cell for quite
some time after the charging has been stopped. Do not smoke or bring a open flame or create
spark in the vicinity of a battery.

Batteries contain sulphuric acid which can cause severe burns, so use protective items like
apron, gloves, gumboot, goggles when working on a battery.

Flush with tap water if acid comes in contact with body parts and seek medical attention
immediately.

Avoid short-circuit of battery it can lead to explosion.

Do not allow any foreign material to go into the battery. Vent holes shall be kept closed with the
vent plugs and the flip top lid shall be opened for taking hydrometer reading or adding water.

2. Safety instructions provided with the help of labels on the product for ease of understanding.

a) It is recommended that safety instruction label with the help of pictures printed on labels be
attached on the product for facilitating the understanding of the people handling the product.

Instructions on Do's & Don'ts may also be provided in text form on the label

A sample label is attached.

Sl. No. Symbol Description

1 Follow user instructions

Wear protective
2
clothing.
Safety glass
Rubber hand gloves
Apron
Gumboots
3
Electrolyte is highly corrosive.

4 Risk of explosion, avoid short-circuits.

5
Avoid open flames and sparks.

6
Run-down accumulators must be recycled.
 DO's:

Match the battery to the correct charger based on the manufacturer's specification. Incorrect
charger can shorten the life of your battery.
Recharge the battery daily unless the battery has been lightly discharged through under
utilisation.
Lift the battery compartment lid while charging to assist ventilation and air-cooling.
Use only approved distilled or de-ionised battery water to top up the battery. Impurities in tap
water can will have a deteriorating effect on the life of the battery.
Keep the battery & tray clean and dry at all times.
Keep all metal connections & bolted terminals tight and covered with a film of petroleum jelly.
Check the condition of charging plug, socket & cable for wear and damage to insulation and
burning of contacts.

DON'TS:

Leaving the battery in a discharged state for more than one day.
Overcharging the battery by recharging more frequently or for longer periods than required to
restore the capacity used.
Removing the cell vent plugs when charging.
Over-top the cells with battery water. Top up electrolyte with battery water to slightly above
the separator level as shown in the fig. Over-topping causes the acid to spill out during charging.
Using metal vessels or jugs to store or dispense battery water or acid.
Adding acid to the cells.
Tamper with the chargers. Any necessary setting or repair should be undertaken only by
qualified personnel.

Material Safety Data Sheet:

A. Product & Company Identification:

Product identity: Lead acid battery
Manufacturer's name: Exide Industries Limited
Address: 59E,Chowringhee Road
Kolkata 700020
Tele: 91 33 2283 2120 / 2133 / 2136 2150 51 /
2171 / 2238 - 39

B. International Maritime Goods Code (IMDG) for wet filled charged lead acid battery:
1. Shipping name of the product: Lead acid battery, wet, filled with acid.
2. Hazardous class: Class 8
3. UN identification: UN2794
4. Packaging group: III
5. Identification label: Corrosive
Composition Information of Ingredients:
Component Hazardous % By weight CAS Number OSHA PEL ACGIH TLV

Lead Yes 40 + / - 10 7439-92-1 0.05mg/m3 0.05mg/m3

Sulphuric Acid Yes 22 + / -10 7664-93-9 1.00mg/m3 1.00mg/m3

Antimony Yes 2+/-1 7440-36-0 0.50mg/m3 0.50mg/m3

Arsenic Yes <1 7440-38-2 0.50mg/m3 0.01mg/m3

Copper Yes <1 7440-50-8 1.00mg/m3 1.00mg/m3

Lead dioxide Yes 27 + / - 5 1309-60-0 0.05mg/m3 0.15mg/m3

Lead sulphate Yes <1 7446-14-2 0.05mg/m3 0.15mg/m3

Non-hazardous component

Polypropylene copolymer No 6+/-2 9003-07-0 N/A N/A

D. Physical & Chemical Characteristics:

Electrolyte (Sulphuric acid)
Solubility in water: Completely soluble
A p p e a ra n c e & o d o u r : C l e a r, o d o u r l e s s , c o l o u r l e s s
S p e c i f i c g ra v i ty ( H 2 O = 1 ) : 1 . 1 3 0 1 . 3 2 0
B o i l i n g p o i n t : A p p r ox i m a t e l y 2 3 5 d e g C
Va p o u r d e n s i t y ( A i r = 1 ) : N / A
E va p o ra t i o n ra t e ( B u t y l a c e t a t e = 1 ) : l e s s t h a n 1 . 0
Va p o u r p r e s s u r e ( m m H g ) : 1 3
Melting point: N/A

E. Reactivity Data:

Stability: Stable
Condition to avoid: Prolonged overcharging, sources of ignition
Incompatibility (Materials to avoid): Sulphuric acid: Contact with
combustibles and organic materials may cause fire and explosion. Also
reacts violently with strong reducing agent, metals, strong oxidizers and
water. Contact with metals may produce toxic sulphur dioxide fumes and
may release flammable hydrogen gas.
Hazardous decomposition of By-Products: Sulphuric acid: Excessive
overcharging or fire may create sulphur trioxide, carbon monoxide,
sulphuric acid mist, sulphur dioxide and hydrogen.
Lead compounds: Contact with strong acid or base or presence of nascent
hydrogen may generate highly toxic arsine gas.
F. Fire & Explosion Hazard Data:

Flash point method used: Non Flammable

E x t i n g u i s h i n g m e d i a : C l a s s A B C e x t i n g u i s h e r, C O 2
F l a m m a b l e l i m i t fo r * H y d r o g e n g a s g e n e ra t e d d u r i n g c h a r g i n g : L E L 4 % H E L 7 4 %
S p e c i a l f i r e f i g h t i n g p r o c e d u r e s : C o o l e x t e r i o r o f b a t t e r y i f e x p o s e d t o f i r e t o p r e ve n t
r u p t u r e . T h e a c i d m i s t a n d va p o u r i n a f i r e s i t u a t i o n a r e c o r r o s i ve . We a r s p e c i a l
r e s p i ra t o r y p r o t e c t i o n a n d c l o t h i n g .
Unusual fire and explosion hazards: *Hydrogen gas, which may explode if ignited, is
p r o d u c e d b y t h i s b a t t e r y, e s p e c i a l l y w h e n c h a r g i n g .
U s e a d e q u a t e v e n t i l a t i o n a vo i d o p e n f l a m e s , s p a r k s , o r o t h e r s o u r c e s o f i g n i t i o n

G. Health Hazard Data:

Note: Under normal condition of battery use, internal components will not pose a
h e a l t h h a z a r d . T h e i n fo r m a t i o n p r ov i d e d h e r e a f t e r fo r b a t t e r y e l e c t r o l y t e ( a c i d ) a n d
l e a d fo r e x p o s u r e t h a t m a y o c c u r d u r i n g b a t t e r y p r o d u c t i o n o r c o n t a i n e r b r e a k a g e o r
under extreme heat conditions such as fire.

C a r c i n o g e n i c i ty :

Sulphuric acid: The International Agency for Research on Cancer (IARC) has
classified “ strong inorganic acid mist containing sulphuric acid as a
category I carcinogen, a substance that is carcinogenic to human beings.
This classification does not apply to liquid form of sulphuric acid contained
within a battery.

Inorganic acid mist (sulphuric acid mist) is not generated under normal use
of this product. Misuse of the product such as overcharging, may result in
the generation of sulphuric acid mist.

Lead compounds: Lead is listed as a 2B carcinogen, likely in animals at

extreme doses. Proof of carcinogenity in human being is lacking at present.
Arsenic: Listed by IARC, OSHA and NIOSH as a carcinogen only after
prolonged exposure at high levels.

Signs and symptoms of exposure : Acid contact may cause irritation of eyes,
nose and throat. Breathing of mist may produce respiratory difficulty.
Contact with eyes and skin causes irritation and skin burns. Sulphuric acid is
a corrosive chemical.
M e d i c a l c o n d i t i o n g e n e ra l l y a g g ra va t e d b y e x p o s u r e : S u l p h u r i c a c i d m i s t e x p o s u r e
m a y a g g ra va t e m e d i c a l c o n d i t i o n s s u c h a s p u l m o n a r y e d e m a , b r o n c h i t i s ,
e m p h y s e m a , d e n t a l e r o s i o n a n d t ra c h e o b r o n c h i t i s . P r e g n a n t w o m e n a n d c h i l d r e n
m u s t b e p r o t e c t e d f ro m l e a d e x p o s u r e .

Emergency and first aid procedures: Sulphuric acid.

a ) F l u s h c o n t a c t e d a r e a w i t h l a r g e a m o u n t s o f w a t e r fo r a t l e a s t 1 5 m i n u t e s .
Re m o ve c o n t a m i n a t e d c l o t h i n g a n d o b t a i n m e d i c a l a t t e n t i o n i f n e c e s s a r y. E m e r g e n c y
s h o w e r s h o u l d b e r e a d i l y a va i l a b l e .

b ) I f s w a l l o w e d , g i v e l a r g e v o l u m e s o f w a t e r. D o n o t i n d u c e v o m i t i n g , o b t a i n
medical treatment.

H. Precautions for Safe Handling and Use:

S t e p s t o b e t a ke n i n c a s e m a t e r i a l i s r e l e a s e d o r s p i l l e d :
Sulphuric acid: Contain the spill with sand & soil and collect the acid absorbed mass
o f s o i l a n d s a n d i n wa t e r t i g h t c o n t a i n e r a n d s e n d t o a u t h o r i z e d wa s t e m a n a g e m e n t
a g e n t . T h e n wa s h t h e s p i l l e d a r e a w i t h d i l u t e wa t e r s o l u t i o n o f n e u t ra l i z i n g a g e n t
l i k e s o d i u m b i c a r b o n a t e o r s o d a a s h o r l i m e a n d f i n a l l y w i t h t a p wa t e r. W h e n
e x p o s u r e l e v e l i s n o t k n o w n , w e a r N I O S H a p p r ov e d p o s i t i v e p r e s s u r e s e l f - c o n t a i n e d
b r e a t h i n g a p p a ra t u s .

Wa s t e d i s p o s a l m e t h o d : L e a d a c i d b a t t e r i e s a r e c o m p l e t e l y r e c yc l a b l e . D i s p o s e o f f
a ny c o l l e c t e d m a t e r i a l i n a c c o r d a n c e w i t h S t a t e o r Fe d e ra l r e g u l a t i o n s .

P r e c a u t i o n s t o b e t a k e n i n h a n d l i n g a n d s t o ra g e : S t o r e a wa y f r o m r e a c t i ve m a t e r i a l
as defined in section D

Other precautions: Sodium bicarbonate, soda ash, sand, or lime should be kept in
s a m e g e n e ra l a r e a fo r e m e r g e n c y u s e . Ke e p a wa y f ro m s o u r c e s o f i g n i t i o n d u r i n g
c h a r g i n g r e fe r s e c t i o n E o n g e n e ra t i o n o f hy d ro g e n g a s . I f a b a t t e r y c a s e i s b r o ke n ,
a vo i d d i r e c t c o n t a c t w i t h i n t e r n a l c o m p o n e n t s .

I. Ecological Information:

AQUATIC TOXICITY

S u l p h u r i c A c i d : To x i c t o f i s h & A l g a e . C o n c e n t ra t i o n s o f 1 0 0 % s u l p h u r i c a c i d g r e a t e r
than 1.2mg/L may be lethal to fish
L o w e r ' p H b e l o w a b o u t 4 w o u l d i n d u c e fa t a l i t i e s i n a q u a t i c l i f e .

Lead compounds: No specific data

J. Control Measures:

Re s p i ra t o r y p r o t e c t i o n : Re s p i ra t o r r e q u i r e d w h e n P E L i s e x c e e d e d o r e m p l o ye e
w i t n e s s e s ' r e s p i ra t o r y i r r i t a t i o n . ( Re fe r s e c t i o n F H e a l t h h a z a r d d a t a )
Ve n t i l a t i o n : M u s t b e p r ov i d e d w h e n c h a r g i n g i n a n e n c l o s e d a r e a .
Mechanical: Acceptable at 1 to 4 air exchanges per hour or to maintain air
c o n c e n t ra t i o n s b e l o w t h e P E L .
L o c a l e x h a u s t : P r e fe r r e d
O t h e r : L o c a l b u i l d i n g / f i r e c o d e s m a y r e q u i r e e x p l o s i o n p r o o f fa n s a n d e q u i p m e n t .

D o n o t f l u s h l e a d - c o n t a m i n a t e d a c i d i n t o s e w e r. D o n o t r e l e a s e u n - n e u t ra l i z e d a c i d .

P r o t e c t i ve g l o ve s : A c i d r e s i s t a n t
E ye p r o t e c ti o n : P r e fe r r e d s a fe ty g l a s s e s , g o g g l e s , fa c e s h i e l d
O t h e r p r o t e c t i ve c l o t h i n g o r e q u i p m e n t : A c i d r e s i s t a n t a p r o n s , b o o t s a n d p r o t e c t i ve
clothing.

K. Other Regulatory Information:

N F PA H a z a r d ra t i n g Sulphuric Acid Lead

Health (Blue) 3 3
F l a m m a b i l i t y ( Re d ) 0 0
Re a c t i v i t y ( Ye l l o w ) 2 0

Ra t i n g s c a l e 0 = I n s i g n i f i c a n t , 1 = S l i g h t , 2 = M o d e ra t e , 3 = H i g h , 4 = E x t r e m e

N o t e : C o n c e n t ra t e d s u l p h u r i c h a s v e r y h i g h a f f i n i ty fo r w a t e r. W h e n p r e p a r i n g d i l u t e
a c i d f r o m c o n c e n t ra t e d a c i d “ A l w ay s a d d a c i d t o w a t e r a n d n e v e r w a t e r t o a c i d “ I n
the second case the whole acid will bump up leading to an explosive situation and
causing accident and damage to persons and object.
Chapter 2:

P r i n c i p l e o f o p e ra t i o n fo r l e a d a c i d b a t t e r y :

I n t ro d u c t i o n :

a ) L e a d a c i d b a t t e r y s t o r e s e l e c t r i c a l p o w e r i n c h e m i c a l fo r m a n d c o n s i s t s o f
multiple cells.
b) Each cell comprises of two dissimilar compounds of lead immersed in dilute
sulphuric acid.
c ) I n i t s fu l l y c h a r g e d s t a t e , t h e a c t i v e m a t e r i a l o f t h e p o s i t i v e p l a t e c o n s i s t s o f
lead di-oxide and that of the negative plate is porous or spongy lead.
d) A lead acid battery is a “secondary battery ” which means that it can be
d i s c h a r g e d a n d r e c h a r g e d a n u m b e r o f t i m e s b e fo r e r e a c h i n g t h e e n d o f
i t s s e r v i c e l i fe .
T h e a b o ve c h a r g e a n d d i s c h a r g e p r o c e s s i s r e p r e s e n t e d b y t h e c h e m i c a l fo r m u l a
given below

Dch

Pb + PbO2 + 2 H2SO4 2 PbSO4 + 2 H2O E cell = 2.0V

Cha

Discharge:

a) When a cell is discharged, sulphuric acid reacts with the active material on the
positive and negative plate. From the reaction on the spongy lead of the negative
p l a t e e l e c t r o n s a r e l i b e ra t e d w h i l s t - Meter
e- e-

- +
Anode Pb PbO2 Cathode

+
H
HSPO4-
H O
2

Discharging Cell

e l e c t r o n s a r e a b s o r b e d b y t h e r e a c t i o n o n t h e l e a d d i ox i d e o n t h e p o s i t i v e p l a t e .
Consequently a current flows between the two plates

a ) B o t h t h e p l a t e s a r e g ra d u a l l y c o nv e r t e d i n t o l e a d s u l p h a t e w h i l e c o n s u m i n g
s u l p h u r i c a c i d f ro m t h e e l e c t r o l y t e . .
Charge:

a) When recharged the sulphate in the active material recombine with the excess
wa t e r i n t h e e l e c t r o l y t e a n d c o nv e r t b a c k t o s u l p h u r i c a c i d . A s a r e s u l t , t h e S. G
i n c r e a s e s b a c k t o i n i t i a l s p e c i f i c g ra v i ty

b ) S i m u l t a n e o u s l y t h e l e a d s u l p h a t e c o nv e r t s t o l e a d d i ox i d e o n t h e p o s i t i v e a n d
s p o n g y l e a d o n t h e n e g a t i v e p l a t e r e s p e c t i ve l y.

e- Direct e-
current
- source +
Cathode Anode
PbO
4

H O
2
+
(some H
HSO4-

Charging Cell

Gassing:

a ) A s t h e c e l l a p p r o a c h e s i t s fu l l y c h a r g e d c o n d i t i o n , t h e c h e m i c a l c o n ve r s i o n c a n
no longer absorb all of the charging current. The surplus current results in the
l i b e ra t i o n o f hy d r o g e n i n t h e n e g a t i v e p l a t e a n d o x yg e n i n t h e p o s i t i v e p l a t e .
b) This process is commonly known as the gassing and is the primary reason why
t h e s e c e l l s n e e d r e g u l a r t o p p i n g u p w i t h w a t e r.
c ) A s t ra c t i o n b a t t e r i e s n e e d t o b e r e c h a r g e d w i t h i n 8 1 2 h o u r s i t i s e s s e n t i a l t o
p a s s o ve r t h e g a s s i n g v o l t a g e u p t o 2 . 6 5 V p c ( T h i s i s n o t a p p l i c a b l e fo r s t a r t e r
b a t t e r i e s a n d s t a n d b y b a t t e r i e s ) . S u b j e c t t o t h e c o n d i t i o n , t e m p e ra t u r e a n d a g e o f
t h e c e l l g a s s i n g n o r m a l l y s t a r t s a t a p p r ox . 2 . 3 5 Vo l t s p e r c e l l .
d ) G a s s i n g a l s o h a s t h e g o o d e f fe c t . I t h e l p s t o a g i t a t e t h e e l e c t r o l y t e i n t h e c e l l
thereby mixing the heavy sulphuric acid with the water in the electrolyte. This
p h e n o m e n o n i s c o m m o n l y k n o w n a s s t ra t i f i c a t i o n .
e ) T h e o p e n c i r c u i t o f a fu l l y c h a r g e d c e l l i s a p p r ox i m a t e l y 2 . 1 3 V. D u r i n g d i s c h a r g e
t h e v o l t a g e fa l l s f r o m 2 . 0 V d o w n t o 1 .7 V fo r t ra c t i o n c e l l s .
f ) D u r i n g c h a r g e t h e v o l t a g e w i l l r i s e f ro m a p p r ox i m a t e l y 2 . 0 V t o a f i n a l va l u e
a p p r o a c h i n g 2 .7 V p c fo r t ra c t i o n c e l l s .
g) The latter voltage is reached when the charging current has dropped to
a p p r ox i m a t e l y 4 - 5 % o f t h e c e l l c a p a c i t y. T h i s i s c a l l e d t h e e n d o f c h a r g e c u r r e n t .

As not all cells are equal its essential that once in every 10 days the batteries
r e c e i ve e q u a l i z i n g c h a r g e i n o r d e r t o g e t t h e c h a r g e c o n d i t i o n & s p e c i f i c g ra v i ty i n
e v e r y c e l l t h e s a m e . T h i s w i l l ke e p t h e b a t t e r y i n o p t i m a l s e r v i c e c o n d i t i o n .
To p p i n g U p w i t h D e - Io n i s e d Wa t e r :

a ) A d i s c h a r g e d b a t t e r y s h o u l d b e p u t o n c h a r g e i m m e d i a t e l y.
b) In every cycle water gets decomposed and the electrolyte level decreases. Its
e s s e n t i a l t h a t y o u t o p u p t h e b a t t e r y w i t h b a t t e r y g ra d e w a t e r.
c) The topping up should be done during charge (once a week) just after the
v o l t a g e i s a b o ve t h e g a s s i n g p o i n t i n o r d e r t o g e t a h o m o g e n e o u s m i x t u r e o f t h e
electrolyte.

Cell Capacity:

a) C e l l c a p a c i t y i s d e p e n d e d u p o n t h e d i s c h a r g e ra t e .

b ) M o t i v e p o w e r b a t t e r i e s a r e ra t e d a t t h e 5 h r d i s c h a r g e ra t e . T h i s m e a n s t h a t a
5 0 0 A h b a t t e r y c a n b e d i s c h a r g e d fo r 5 h o u r s a t 1 0 0 A t o a c u t o f f v o l t a g e o f
1 .7 V p c . T h i s i s t h e 1 0 0 p e r c e n t d e p t h o f d i s c h a r g e c o n d i t i o n a n d t h e s p e c i f i c g ra v i ty
of the electrolyte will reach 1.130 level.
c) During discharge in service the battery voltage should not be allowed to drop
b e l o w 1 . 8 4 v o l t a n d s p e c i f i c g ra v i ty o f 1 . 1 6 0 w h i c h i s t h e 8 0 p e r c e n t d e p t h o f
discharge condition
d ) H i g h e r o r l o w e r ra t e s o f d i s c h a r g e h a ve l o w e r a n d h i g h e r c u t o f f v o l t a g e p o i n t s
r e s p e c t i ve l y.

T h e e x t e n t o f d i s c h a r g e i s b e t t e r i n d i c a t e d b y s p e c i f i c g ra v i ty r e a d i n g w h i c h h a s a
linear relationship to extent of discharge.

Special Gravity
1.3

1.25

1.2
SP Gravity

Specific Gravity

1.15

1.1

1.05

0.05h 1h 1.5h 2h 2.5h 3h 3.5h 4h 4.5h 5h 5.25h

Hours
Life of the Battery:

a ) B a t t e r y l i f e d e p e n d s o n m a ny fa c t o r s o f w h i c h t e m p e ra t u r e , q u a l i t y o f t o p p i n g u p
w a t e r, d e p t h o f d i s c h a r g e ( 8 0 p e r c e n t m a x i m u m 8 0 p e r c e n t d e p t h o f d i s c h a r g e i s
e q u i va l e n t t o 1 . 1 6 0 s p g ra v i ty a n d 1 . 8 4 v o l t p e r c e l l v o l t a g e r e a d i n g ) p r o p e r
charging and regular maintenance are of major importance.

b ) T h e c y c l e l i f e d e c l a r e d b y t h e m a n u fa c t u r e r o f t h e b a t t e r y i s a c h i e va b l e i f t h e
fo l l o w i n g c o n d i t i o n s a r e m e t w i t h . ( Re fe r e n c e t e s t i n g s t a n d a r d I E C 6 0 2 5 4 1 )

i ) Av e ra g e o p e ra t i n g t e m p e ra t u r e o f 3 8 d e g C . I f t h e a ve ra g e o p e ra t i n g
t e m p e ra t u r e r i s e s b y 1 0 o c e n t i g ra d e a b o ve 3 8 o C , t h e a va i l a b l e l i f e o f t h e b a t t e r y
will get reduced by 50 percent.

Re m e d i a l a c t i o n A m b i e n t c l i m a t i c c o n d i t i o n o f a g e o g ra p h i c a l l o c a t i o n c a n n o t b e
changed and in places having hotter ambient, the life will get reduced. The other
r e a s o n fo r h i g h t e m p e ra t u r e i s d u e t o h e a t b u i l d u p i n t h e c h a r g i n g p r o c e s s . T h i s i s
t h e I 2 R c o m p o n e n t i n a ny p r o c e s s o f e l e c t r i c i t y f l o w. U s e o f A i r c i r c u l a t i o n i n t h e
e l e c t r o l y t e d u r i n g t h e c h a r g e c y c l e c a n b e o f h e l p . T h i s i s a n o p t i o n a l k i t a va i l a b l e
o n o r d e r. A l s o, h i g h e r o p e ra t i n g t e m p e ra t u r e o f t h e b a t t e r y c a n b e a vo i d e d b y
maintaining multiple battery per truck. 2.5 batteries minimum to 3 batteries per
t r u c k i s a r e c o m m e n d e d p ra c t i c e fo r a 2 4 / 7 o p e ra t i o n i . e . w h e r e t h e o p e ra t i o n i s
r o u n d t h e c l o c k a n d fo r 3 6 5 d a y s o f a n y e a r. T h i s a l l o w s t h e b a t t e r y t o c o o l d o w n
after charging.

i i ) Q u a l i t y o f t o p p i n g u p wa t e r. I ro n , M a n g a n e s e a n d C h l o r i n e a r e p o i s o n i n g
m a t e r i a l fo r l e a d a c i d b a t t e r y a n d t h r o u g h c o m p l e x c h e m i c a l r e a c t i o n r e d u c e s t h e
w o r k i n g l i f e o f t h e b a t t e r y.
Re m e d i a l a c t i o n U s e w a t e r i n w h i c h t h i s c h e m i c a l s a r e ke p t t o a m i n i m u m l e v e l b y
t h e p r o c e s s k n o w n a s d i s t i l l a t i o n o r d e m i n e ra l i s a t i o n . Re f e r c h a p t e r 3 / s e c t i o n ( f )
fo r p u r i t y s p e c i f i c a t i o n o f w a t e r.

i i i ) D e p t h o f d i s c h a r g e e x c e e d i n g 8 0 p e r c e n t o f t h e ra t e d c a p a c i t y l e a d s t o
c o n ve r s i o n o f t h e a c t i v e m a t e r i a l t o a n i r r e c o ve ra b l e s t a t e k n o w n a s ' r e ve r s a l ' . T h i s
i s t h e i n t r i n s i c c h e m i s t r y o f t h e l e a d a c i d s y s t e m a n d c a n n o t b e a vo i d e d .

Re m e d i a l a c t i o n U s e o f B a t t e r y d i s c h a r g e i n d i c a t o r w h i c h g i v e s a n a l a r m t o t h e u s e r
that the battery is close to exhausted condition and needs recharging.

i v ) P r o p e r c h a r g i n g T h e wa t t a g e o f e l e c t r i c i t y t o b e fe d t o t h e b a t t e r y w i l l b e m o r e
t h a n t h e w a tt a g e e x t ra c t e d f r o m t h e b a t t e r y i n t h e p r e v i o u s d i s c h a r g e c y c l e . N o
system is 100 percent or more efficient as understood from basic thermodynamics of
e n e r g y w o r k r e l a t i on s h i p.
E n s u r e fe e d i n g t h e e x t ra a m o u n t o ve r t h e d i s c h a r g e d A h . W i t h a g o o d d e s i g n a n d
c o n t r o l o ve r t h e b a t t e r y m a n u fa c t u r i n g p r o c e s s , b a t t e r i e s o f h e i g h t u p t o 5 0 0 m m
n o m i n a l s h o u l d n e e d 1 5 p e r c e n t e x t ra . C e l l s o f t a l l e r h e i g h t s w i l l n e e d a b o u t 2 5
p e r c e n t e x t ra . W i t h o u t t h i s e x t ra c h a r g e , c e l l s i n t h e b a t t e r y w i l l r e m a i n
incompletely charged and start accumulating lead sulphate. If a battery continues to
a c c u m u l a t e s u l p h a t e , a t o n e p o i n t o f t i m e , i t c a n r e a c h a s i t u a t i o n f ro m w h e r e t h e
b a t t e r y w i l l n o t b e a b l e t o r e c ov e r b a c k a n d w i l l h a ve a p e r m a n e n t l o s s i n c a p a c i t y.
W i t h t h e a g e o f t h e b a t t e r y t h e r e q u i r e m e n t o f t h e e x t ra a m o u n t o f c h a r g e w i l l
i n c r e a s e t o b r i n g b a c k t h e b a t t e r y t o fu l l y a c t i va t e d c o n d i t i o n .

Re m e d i a l a c t i o n S e l e c t a m a t c h i n g c h a r g e r fo r t h e b a t t e r y. Ta k e h e l p o f t h e d e a l e r
o r t h e m a n u fa c t u r e r o f t h e b a t t e r y i n i d e n t i f i c a t i o n o f t h e c h a r g e r ra t i n g t o e n s u r e
i t s s u i t a b i l i t y fo r t h e p u r p o s e .

M a i n t a i n r e c o r d s fo r t h e c h a r g e a n d d i s c h a r g e s . D a t a - l o g g e r s a r e a va i l a b l e n o w,
w h i c h c a n l o g d a t a a n d l a t e r o n d o w n l o a d t o c o m p u t e r f i l e s . O r e l s e , m a n u a l r e c o rd
o f t h e c h a r g e / d i s c h a r g e a n d o t h e r p a ra m e t e r s o f t h e b a t t e r y b e m a i n t a i n e d a n d a c t
b a s e d o n t h e o b s e r va t i o n .

E q u a l i s i n g c h a r g e I n t h e p r e v i o u s p a ra g ra p h , t h e c h a r g i n g i n p u t s m e n t i o n e d c a n b e
c a l l e d a s s e r v i c e c h a r g e , w h i c h i s p r ov i d e d i n b e t w e e n d i s c h a r g e s . E q u a l i s i n g c h a r g e
i s b a s i c a l l y a n e x t e n d e d c h a r g e a t a l o w c u r r e n t a f t e r t h e s e r v i c e c h a r g e , p r ov i d e d t o
bring all the cells in a battery to an equal condition of charge. Batteries should be
e q u a l i s e d b a s e d o n t h e d i f fe r e n c e n o t e d i n s p e c i f i c g ra v i ty i n t h e c e l l s a f t e r
charging . A new battery is expected to work with equalisation done once a month
a n d t h e f re q u e n c y w i l l i n c r e a s e w i t h a g e o f t h e b a t t e r y a n d m a y b e r e q u i r e d t o b e
equalised once a week at the later stage.

v ) O v e rc h a r g i n g D u r i n g t h e c h a r g i n g p r o c e s s , t h e p o s i t i v e p l a t e s u p p o r t o f t h e
b a t t e r y g e t s c o r r o d e d . T h i s i s a n u n i n t e n d e d r e a c t i o n b u t c a n n o t b e a vo i d e d
i n t r i n s i c o f t h e l e a d a c i d b a t t e r y s y s t e m . O n l y e x c e s s i ve , u n n e c e s s a r y c o r r o s i o n
p r o c e s s c a n b e a vo i d e d b y m o n i t o r i n g t h e c h a r g i n g p r o c e s s . U s e o f r e g u l a t e d
chargers will be beneficial.

Re m e d i a l a c t i o n M a n u a l o r a u t o m a t i c m o n i t o r i n g o f t h e c h a r g i n g p r o c e s s a n d
t e r m i n a t i o n h a s t o b e d o n e . Fo r l e a d a c i d b a t t e r y, s p e c i f i c g ra v i ty o f t h e e l e c t r o l y t e
i s t h e b e s t i n d i c a t o r fo r m o n i t o r i n g t h e c h a r g e a s i t h a s a n a l m o s t l i n e a r r e l a t i o n s h i p
w i t h e x t e n t o f c h a r g e . C h a r g i n g s h a l l h a ve t o b e t e r m i n a t e d w h e n t h e r e i s n o fu r t h e r
i n c r e a s e i n s p e c i f i c g ra v i ty i e a l l t h e s u l p h a t e s i n t h e p l a t e i s r e l e a s e d b a c k i n
t h e e l e c t r o l y t e . A u t o m a t i c c h a r g e r s h a ve m i c r o p r o c e s s o r s , w h i c h c a l c u l a t e t h e
d e r i va t i v e o f t h e b a t t e r y v o l t a g e w i t h t i m e a n d s t o p s t h e c h a r g i n g p r o c e s s w h e n t h e
i n c r e a s e i s fo u n d t o b e z e r o o r i n s i g n i f i c a n t . T h e s e c h a r g e r s a r e k n o w n t o h a ve d v / d t
fu n c t i o n t o t e r m i n a t e c h a r g e .

Note: The maintenance of lead acid battery being a specialized job ,users are
a d v i s e d t o a va i l s e r v i c e f r o m t h e e x p e r t . M a n u fa c t u r e r s a n d t h e i r d e a l e r s o f fe r
s e r v i c e p a c k a g e i n fo r m o f 'A n n u a l M a i n t e n a n c e C o n t ra c t ' , w h i c h m a y b e a va i l e d t o
g e t b e t t e r l i f e o u t o f t h e b a t t e r y.
b a t t e r y w i l l n o t b e a b l e t o r e c ov e r b a c k a n d w i l l h a ve a p e r m a n e n t l o s s i n c a p a c i t y.
W i t h t h e a g e o f t h e b a t t e r y t h e r e q u i r e m e n t o f t h e e x t ra a m o u n t o f c h a r g e w i l l
i n c r e a s e t o b r i n g b a c k t h e b a t t e r y t o fu l l y a c t i va t e d c o n d i t i o n .

Re m e d i a l a c t i o n S e l e c t a m a t c h i n g c h a r g e r fo r t h e b a t t e r y. Ta k e h e l p o f t h e d e a l e r
o r t h e m a n u fa c t u r e r o f t h e b a t t e r y i n i d e n t i f i c a t i o n o f t h e c h a r g e r ra t i n g t o e n s u r e
i t s s u i t a b i l i t y fo r t h e p u r p o s e .

M a i n t a i n r e c o r d s fo r t h e c h a r g e a n d d i s c h a r g e s . D a t a - l o g g e r s a r e a va i l a b l e n o w,
which can log data and later on down load to computer files. Or else, manual record
o f t h e c h a r g e / d i s c h a r g e a n d o t h e r p a ra m e t e r s o f t h e b a t t e r y b e m a i n t a i n e d a n d a c t
b a s e d o n t h e o b s e r va t i o n .

E q u a l i s i n g c h a r g e I n t h e p r e v i o u s p a ra g ra p h , t h e c h a r g i n g i n p u t s m e n t i o n e d c a n b e
c a l l e d a s s e r v i c e c h a r g e , w h i c h i s p r ov i d e d i n b e t w e e n d i s c h a r g e s . E q u a l i s i n g c h a r g e
i s b a s i c a l l y a n e x t e n d e d c h a r g e a t a l o w c u r r e n t a f t e r t h e s e r v i c e c h a r g e , p r ov i d e d t o
bring all the cells in a battery to an equal condition of charge. Batteries should be
e q u a l i s e d b a s e d o n t h e d i f fe r e n c e n o t e d i n s p e c i f i c g ra v i ty i n t h e c e l l s a f t e r
charging . A new battery is expected to work with equalisation done once a month
a n d t h e f re q u e n c y w i l l i n c r e a s e w i t h a g e o f t h e b a t t e r y a n d m a y b e r e q u i r e d t o b e
equalised once a week at the later stage.

v ) O v e rc h a r g i n g D u r i n g t h e c h a r g i n g p r o c e s s , t h e p o s i t i v e p l a t e s u p p o r t o f t h e
b a t t e r y g e t s c o r r o d e d . T h i s i s a n u n i n t e n d e d r e a c t i o n b u t c a n n o t b e a vo i d e d
i n t r i n s i c o f t h e l e a d a c i d b a t t e r y s y s t e m . O n l y e x c e s s i ve , u n n e c e s s a r y c o r r o s i o n
p r o c e s s c a n b e a vo i d e d b y m o n i t o r i n g t h e c h a r g i n g p r o c e s s . U s e o f r e g u l a t e d
chargers will be beneficial.

Re m e d i a l a c t i o n M a n u a l o r a u t o m a t i c m o n i t o r i n g o f t h e c h a r g i n g p r o c e s s a n d
t e r m i n a t i o n h a s t o b e d o n e . Fo r l e a d a c i d b a t t e r y, s p e c i f i c g ra v i ty o f t h e e l e c t r o l y t e
i s t h e b e s t i n d i c a t o r fo r m o n i t o r i n g t h e c h a r g e a s i t h a s a n a l m o s t l i n e a r r e l a t i o n s h i p
w i t h e x t e n t o f c h a r g e . C h a r g i n g s h a l l h a ve t o b e t e r m i n a t e d w h e n t h e r e i s n o fu r t h e r
i n c r e a s e i n s p e c i f i c g ra v i ty i e a l l t h e s u l p h a t e s i n t h e p l a t e i s r e l e a s e d b a c k i n
t h e e l e c t r o l y t e . A u t o m a t i c c h a r g e r s h a ve m i c r o p r o c e s s o r s , w h i c h c a l c u l a t e t h e
d e r i va t i v e o f t h e b a t t e r y v o l t a g e w i t h t i m e a n d s t o p s t h e c h a r g i n g p r o c e s s w h e n t h e
i n c r e a s e i s fo u n d t o b e z e r o o r i n s i g n i f i c a n t . T h e s e c h a r g e r s a r e k n o w n t o h a ve d v / d t
fu n c t i o n t o t e r m i n a t e c h a r g e .

Note: The maintenance of lead acid battery being a specialized job ,users are
a d v i s e d t o a va i l s e r v i c e f r o m t h e e x p e r t . M a n u fa c t u r e r s a n d t h e i r d e a l e r s o f fe r
s e r v i c e p a c k a g e i n fo r m o f 'A n n u a l M a i n t e n a n c e C o n t ra c t ' , w h i c h m a y b e a va i l e d t o
g e t b e t t e r l i f e o u t o f t h e b a t t e r y.
Chapter 3:

P r e p a r i n g a b a tt e r y fo r s e r v i c e :

A . T h e d r y c h a r g e d b a t t e r i e s a r e s u p p l i e d c h a r g e d a n d i n d r y c o n d i t i o n w i t h o u t a ny
electrolyte in the cells. (On request , batteries filled with electrolyte and ready to
u s e c a n b e s u p p l i e d ) . E a c h c e l l i s c l o s e d b y a t ra n s p o r t c a p , i f s u p p l i e d i n d r y
c o n d i t i o n d u r i n g t h e s t o ra g e t o p r o t e c t t h e n e g a t i v e p l a t e f ro m ox i d a t i o n . S t o r e t h e
c e l l s o r t h e b a t t e r y i n a c o o l a n d d r y p l a c e p r o t e c t e d f ro m m o i s t u r e , ra i n a n d s n o w.
D o n o t s t o r e m o r e t h a n t w o y e a r s . I t i s i m p o r t a n t n o t t o r e m ov e t h e c a p s .

B. The battery installation and the charging equipment should be inspected to

ensure that they are in good mechanical condition. All cables must be connected to
ensure a good contact , taking care that the polarity is correct .All threaded
connectors in the battery must be checked and tightened in order to ensure a
reliable contact. The tightening torque shall be 25 +/- 2 Nm (Newton meter).

If the batteries are of welded connector version , the welding of the connectors
s h a l l b e d o n e i n a s a fe p l a c e a wa y f ro m i n f l a m m a b l e i t e m s a n d n e v e r i n t h e
b a t t e r y c h a r g i n g f l o o r.

C . I f t h e c e l l s a r e s u p p l i e d l o o s e , t h e b a t t e r y h a s t o b e a s s e m b l e d i n b a t t e r y c ra t e
a s p e r l a yo u t i n s t r u c t i o n s f r o m t h e c u s t o m e r . T h e f i l l i n g a c i d s h a l l h a ve t o c o m p l y
t o t h e s p e c i f i c a t i o n g i v e n b e l o w.

T h e m a x i m u m l i m i t s o f i m p u r i t i e s i n b a t t e r y g ra d e s u l p h u r i c a c i d a n d w a t e r a r e a s
fo l l o w s .

Matter Battery Grade water Battery Grade 2SO4

Suspended matter Nil Nil

Iron 0.1 ppm 14 ppm

Chlorine 1 ppm 7 ppm

Manganese 0.1 ppm Nil

Total dissolved solid 2 ppm Nil

Electrical conductivity at 5 max. Not applicable

27 ± 2oC(micro-mho / cm)

PH 6 7.5 Not applicable

N o m i n a l s p e c i f i c g ra v i ty t o b e o b t a i n e d a f t e r c h a r g e i s 1 . 2 9 0 a t 3 0 d e g C a n d t h e
f i l l i n g a c i d g ra v i ty s h a l l b e 2 0 t o 3 0 u n i t l e s s t h a t i s 1 . 2 6 0 t o 1 . 2 7 0 a t 3 0 d e g C . T h e
t e m p e ra t u r e o f t h e f i l l i n g a c i d s h a l l b e w i t h i n 1 5 t o 3 0 d e g C .
Te m p e ra t u r e c o r r e c t i o n fa c t o r fo r d i l u t e s u l p h u r i c a c i d .

S p e c i f i c g ra v i ty a t 3 0 d e g C = S p g ra v i ty a t ' T ' d e g C + ( T - 3 0 ) X 0 . 0 0 0 7

B . E l e c t r o l y t e L e v e l Re m o ve t h e t ra n s p o r t c a p s a n d f i l l t h e c e l l s w i t h t h e s p e c i f i e d
acid until the stepped level in the plug basket is reached. Acid resistant filling
e q u i p m e n t t o b e u s e d . Tra n s p o r t c a p s a r e n o t t o b e u s e d w i t h t h e c e l l s d u r i n g
c h a r g i n g a n d d u r i n g t h e s e r v i c e o f t h e b a t t e r y . O n c e r e m ov e d f ro m t h e c e l l s t h e
t ra n s p o r t c a p s h a l l b e d e s t r o ye d t o p r e ve n t i n a d v e r t e n t u s a g e w h i c h c a n l e a d t o
b u r s t i n g o f c e l l a n d c a u s e a c c i d e n t a n d d a m a g e . T h e t ra n s p o r t c a p s a r e t o b e
r e p l a c e d b y v e n t p l u g s a s s h o w n i n t h e p i c t u r e b e l o w o r wa t e r i n g p l u g s .

Electrolyte Level

C . Re s t p e r i o d A f t e r f i l l i n g t h e c e l l s t h e b a t t e r y s h o u l d s t a n d fo r a p e r i o d o f 4
h o u r s fo r i m p r e g n a t i o n o f t h e p l a t e s a n d s e p a ra t o r s . D u r i n g t h e r e s t p e r i o d c h e c k
the cell polarity with a multi-meter and compare with that on the cell lid. If the
m u l t i - m e t e r r e a d s r e ve r s e v o l t a g e , t a k e o u t t h e c e l l a n d r e p l a c e w i t h a f r e s h c e l l
a n d r e p o r t t h e d e fe c t t o t h e m a n u fa c t u r e r. C h e c k t h e t i g h t n e s s o f t h e fa s t e n e r s .
Place the vent plugs with level indicators. Fill in to the level shown in the picture.
Connect the end terminal socket on the batteries correctly to the charger socket to
a vo i d r e ve r s e c h a r g i n g . T h e t e m p e ra t u r e , v o l t a g e a n d s p e c i f i c g ra v i ty s h a l l b e
r e c o r d e d fo r a l l t h e c e l l s d u r i n g t h e c o m m i s s i o n i n g c h a r g e a t a n h o u r l y i n t e r va l .

D. C o m m i s s i o n i n g : T h e f i r s t c h a r g e o f t h e b a t t e r y h a s t o b e d o n e fu l l y a n d a s fa r
a s p o s s i b l e w i t h o u t i n t e r r u p t i o n s . T h e t e m p e ra t u r e o f t h e e l e c t r o l y t e m u s t n o t
e x c e e d 5 5 d e g C , a n d i f i t d o e s t h e c h a r g i n g h a s t o b e s t o p p e d . Re s u m e c h a r g e
a f t e r t h e t e m p e ra t u r e c o m e s d o w n b y 5 d e g C . T h e c o m p l e t i o n o f t h e c h a r g i n g i s
i n d i c a t e d b y f re e g a s s i n g i n a l l t h e c e l l s a n d t h r e e c o n s e c u t i v e h o u r l y r e a d i n g o f
v o l t a g e a n d s p e c i f i c g ra v i ty s h o w i n g n o c h a n g e . T h e r e c o r d fo r c e l l v o l t a g e s p e c i f i c
g ra v i ty a n d t e m p e ra t u r e fo r a l l t h e c e l l s h a ve t o b e r e c o r d e d a n d p r e s e r ve d .

The battery can be charged at constant current with the current maintained
between 6 to 10 percent of the battery ampere hour till the end conditions are
reached.
T h e b a t t e r y c a n a l s o b e c h a r g e d w i t h a c o n s t a n t v o l t a g e c o n s t a n t c u r r e n t ty p e
charger .The battery shall be started in a constant potential charging mode the
voltage set at 2.4 volt per cell with an initial limit current setting of 16 percent of
b a t t e r y a m p e r e - h o u r. T h e c h a r g i n g s w i t c h e s o ve r t o c o n s t a n t c u r r e n t w h e n t h e
voltage reaches 2.4 volt and the current maintained at 6 percent of Battery Ah. The
v o l t a g e p i c k s u p t o 2 . 6 5 m i n i m u m fo r a l l t h e c e l l s a n d t h e n s e t a t c o n s t a n t p o t e n t i a l
of 2.65 volt per cell till the current tapers down to 3 percent of Battery Ah. This
step can be controlled through timer setting of 3 to 4 hours .The important points to
note is that all the cells reaches the end of charge condition.

E . E l e c t r o l y t e l e v e l a n d s p e c i f i c g ra v i ty a d j u s t m e n t . T h e s p e c i f i c g ra v i ty o f a l l t h e
cells are likely to come between +/- 0.010 Kg / L. Allow the battery to cool down
and check the electrolyte level and adjust to the level mentioned. If the Specific
g ra v i ty o f t h e e l e c t r o l y t e i s fo u n d t o b e h i g h e r t h a n t h e s p e c i f i c a t i o n , w i t h d ra w
s o m e q u a n t i t y o f e l e c t r o l y t e a n d t o p u p w i t h b a t t e r y g ra d e w a t e r.

F. S p i l l e d a c i d m u s t b e c a r e fu l l y n e u t ra l i z e d w i t h n e u t ra l i z i n g a g e n t a n d d i s p o s e d
o f f a c c o r d i n g t o t h e p r e va l e n t r e g u l a t i o n i n t h e c o u n t r y o f u s e . N e u t ra l i z i n g a g e n t
should not go into the cells.
 C h e c k l i s t fo r r e g u l a r c h e c k s fo r l e a d a c i d t ra c t i o n b a t t e r y :

B a t t e r y v o l t a g e & A h ra t i n g :

Battery serial no:

Date of installation:

C h e c k Po i n t Check date

1) Battery end terminal connection tightness

2) Connections free from sulphation

3) To p l e a d c o n n e c t o r s o r b o l t o n c o n n e c t o r s

protected with anti-sulphuric grease

4) Equal level of electrolyte in all the cells

5) S p e c i f i c g ra v i ty b e f o re p u t t i n g o n c h a r g e

6) S p e c i f i c g ra v i ty a f t e r c h a r g e

7) Te m p e ra t u r e a t t h e e n d o f t h e c h a r g e i n p i l o t c e l l s

9) Date of equalising charge

N o t e : N o n - a d h e r e n c e t o t h e s e b a t t e r y m a i n t e n a n c e i n s t r u c t i o n s n u l l i f i e s t h e wa r ra n ty.