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xtrapowerbatteries.com / Info Center / Maintenance

maintenance

Receiving the Battery :

Establishing Requirements
The number of batteries required for service depends primarily upon the number of 8-hour shifts in effect. Normally, for operation on a single shift basis, the minimum number of batteries required will be the same as the number of items of operating equipment and the batteries need not be removed from the truck for charging. For operation on a 2 or 3 shift basis, the minimum number of batteries required will be twice the number of items of operating equipment and it will, therefore, be necessary to exchange discharged batteries for charged batteries at the end of each work shift. Whenever possible, it is recommended that more than the minimum number of batteries be available for multiple shift operation. This will provide at least 8 hours of rest, after charging, as a cooling period. In an emergency any one battery can be used for two 8 hour shifts during a 24 hour period, but if this is repeated regularly it probably will cause high electrolyte temperatures and could seri- ously effect service life. Therefore, where 3 shift opera- tion is normal, 3 batteries will be required per item of equipment.

Unpacking Upon Receipt
a. It is important first to examine the exterior of the packing for wet spots on bottom or sides which may indicate leaking jars which could have been broken in shipment. Inspect also for physical damage to battery package which could mean that the battery was effected as well. Report any damage to the superior officer in charge.
b. Make certain that the package is right side up with skid mounts resting firmly on floor.
c. Use a forklift truck or crane of sufficient capacity to remove the packaged battery from the truck or freight car. If a crane is employed be sure the sling is secured against the bottom of the skid and not around the skid mounts.
d. Move the crated battery to the uncrating area and remove packaging, including any wrapping or other protection provided to the battery terminal cable con nectors.
e. Inspect battery and report any damage to the superior officer in charge.
f. A properly insulated lifting beam of adequate capacity should be used to lift the battery, by means of an overhead hoist, from the battery skid.

Handling Batteries
At all times, when lifting batteries, use a device which exerts a vertical pull on the lifting eye or tab. If a chain must be used, it should be in combination with a lifting beam with provision for adjusting lifting hook centers to the exact length of the tray. Any method of lifting which tends to “squeeze” or “stretch” the battery tray may distort it and could damage jars or disturb cell seals. A piece of rubber sheet, or other insulating material, temporarily laid on the battery while lifting, will prevent any possible short circuits from chains or hooks. As an additional precaution against accidental shorting, the lifting beam hooks should be electrically insulated from each other.-1. Lifting beam

Preparing Batteries for Use
Batteries are shipped either “charged and dry” or “charged and wet.” They vary considerably, of course, in their preparation needs.

Charged and Dry Batteries
Charged and dry batteries are shipped with plates which have been charged and dried, dry separators and without electrolyte in the cells. The vent openings of all cells are sealed and must remain so until the battery is being prepared for service. Charged and dry batteries must be properly activated. Prepare these batteries for use as follows:

(1) Remove all vent caps and destroy the sealing device, red tape or other material used to seal the vent cap holes. Make certain that all vent openings will permit free passage of gas.
(2) Fill each cell to the proper level with electrolyte and having a specific gravity 15 points (.015) lower than the designated fully charged specific gravity unless otherwise specified by the manufacturer.

For example, if the fully charged specific gravity is to be 1.285 the filling acid should be 1.270. See Table 2-1 for Proportions of Sulfuric Acid and Water. Allow the cells to stand for at least several hours after filling, then adjust electrolyte levels so they are 1/4” to 3/8” below the bottom of the vent well or skirt. Replace the vent caps.

The temperature of the filling electrolyte must not exceed 90 degrees F.

(3) Clean the cell tops if any electrolyte was spilled. Neutralize with soda solution (one pound of baking soda to one gallon of water), rinse with water and dry thoroughly.
(4) Give the battery a freshening charge. Be sure to continue the charge until the specific gravity remains constant for three consecutive hourly readings.
(5) Recheck electrolyte levels after gassing of elec- trolyte has stopped and take and record specific gravity reading, electrolyte temperature and open circuit voltage of each cell. If irregularities in specific gravity readings exist, they should be adjusted . Adjust electrolyte levels so they are 1/8” to 1/4” below vent well skirt.
(6) Each battery manufacturer's instructions will provide additional detail. Follow these instructions to assure compliance with any special requirements.

Charged and Wet Batteries
Charged and wet bat- teries are shipped with cells filled and fully charged. Prepare these batteries for use as follows:

(1) Examine battery to see if electrolyte has been accidentally spilled. If so, clean and neutralize any spillage with a cloth which has been dipped in a soda solution. Rinse with clear water and dry battery thoroughly.
(2) Remove vent caps and check the electrolyte level in each cell. Take and record the specific gravity reading, electrolyte temperature and individual open circuit voltage of each cell. Note any irregularities.
(3) Check to make sure that all cells are properly connected and that terminal connections are tight. If there are irregularities in the electrolyte levels or specific gravity readings or if the battery has been in storage for more than 30 days, it should be given a freshening charge.
(4) Recheck electrolyte levels after charging and after gassing has stopped. Again take and record specific gravity readings and electrolyte temperatures. After the battery has been standing for at least one hour, also take and record the open circuit voltage of each cell. If irregularities in electrolyte specific gravity readings still exist, they should be adjusted.

Battery Cleaning:

The modern industrial battery is designed and built to give an average of 1500 cycles of charge and discharge during its life, depending upon the application and the operating environment. The exact length of the service life will depend, to a great extent, upon the care the battery receives. The following maintenance procedures, carried out at the proper time, will do much to prolong the life of the battery and provide efficient, satisfactory service.

Charger Adjustment
Make sure that the charger adjustment, for control of charging rates and cut-off are correct. This will assure that the batteries are properly charged with no excessive over-charge. Batteries that are overcharged regularly will need water more often, and cell temperatures usually will be higher than normal. If either condition is evident, adjust the charge rate downward, in those chargers which have provision for adjustment, so it is between a normal finish rate and one-half normal finish rate. Also check the adjustment of the ampere-hour meter and temperature- voltage relay, if either are used, as well as the timer switch.

Cleaning a Battery
Inspect the battery at least once each month to make certain terminal connections are tight. Remove dirt or electrolyte accumulation from the tops of the cells. Wash with clean water and dry. Using a solution of baking soda and water (one pound of baking soda to one gallon of water) neutralize any acid which may be collected at cell or battery terminals to keep them free from corrosion. b. Use the solution until all fizzing stops. Work the solution under the connectors with a clean paint brush. To remove all traces of soda solution and loose dirt, rinse the battery down with clear water from a low pressure hose. Whenever the battery top is being cleaned or rinsed, vent caps must be tightly in place.

Battery Gassing:

Control of Gassing
Gassing is the evolution of gases from one or more of the electrodes during electrolysis. It is a natural phenomenon which takes place when a battery on charge can no longer accept all of the current being applied to it. Gassing is evidenced by bubbling of the electrolyte. The gases liberated are oxygen, evolved at the positive plates, and hydrogen, evolved at the negatives.

The point at which significant gassing begins is determined by voltage, but the amount of gas depends upon the portion of the charging current that is not being absorbed by the battery. Normally, noticeable gassing will begin when the voltage exceeds 2.30 volts per cell. At 2.40 volts per cell gassing will be normal and at 2.50 it will be rapid. The amperage at which gassing becomes excessive depends primarily upon the state of charge and electrolyte temperatures. As the battery approaches full charge, it is necessary, therefore, to reduce the charging rate to a point at which excessive gassing is prevented. This safe rate is the finishing rate. When proper charging equipment is used the tapering of the charging current to the finishing rate is achieved automatically. Manufacturers instructions will normally prescribe the desired charging rates.

Battery Watering:

Adding Water
A certain amount of water loss in cells is normal and it should be replaced with “pure” tap water or distilled water. In some geographical areas tap water may contain chemicals or other impurities harmful to batteries. The NEMA recommendation for battery replacement water lists the following maximum allowable impurities (parts per million) :

Total solids 350 PPM
Chlorides as C1 25 PPM
Nitrates as NO 3 10 PPM
Iron as Fe 4 PPM

Most industrial truck battery manufacturers provide water analysis service. A minimum sample of one quart is required

Check the height of the electrolyte at least weekly and, if water is needed, add just enough to bring the electrolyte to proper level. Do not overfill. Never fill cells to above the bottom of the vent well or skirt. To avoid overfilling, it is best to add water at the end of a charge.

Water should be added often enough to prevent the electrolyte level from dropping below the perforated separator protector. Ideally a watering schedule should be established. This would assure adequate watering while taking into consideration those factors which control water consumption, such as:

(1) frequency of charging,
(2) water storage capacity of the specific cell type and
(3) age and condition

Battery Readings :

Taking Hydrometer Reading
a. Squeeze the syringe bulb and then slowly release it, drawing into the cylinder or barrel just enough electrolyte to permit the hydrometer float to ride free. The float stem must not touch the side of the cylinder nor the top of the syringe. If the float stem touches the upper area of the syringe, too much electrolyte has been drawn up; if the float still rests on the bottom, too little electrolyte has been drawn up.
b. Read the hydrometer float scale with eye at same level as electrolyte. The reading should be taken at the surface of the liquid disregarding any slight curvature. This reading will be the specific gravity of the electrolyte uncorrected for temperature. See Table 2-2 for correction factors.
c. Return all electrolyte to cell.

Record Keeping
Facilities with more than just a few batteries will find that records of battery cycles, maintenance and repair are indispensable for an effective battery maintenance pro- gram. In addition to those monthly records referenced in Paragraph 1-2d, which require the posting of data each time a battery is charged, the following procedure will be helpful:

a. Establish a battery identification system giving each battery a code number. A multiple-digit system is sug- gested such as 1201, 1202, etc., for all 12 volt 375 ampere-hour batteries, and 3601, 3602, etc., for all 36 volt 750 ampere-hour batteries etc.

b. Record specific gravity of the pilot cell or cells before and after each charge. Pilot cells should be selected from those nearest the center of the battery and identified by differently colored vent caps. They should be representative of the balance of the cells in the battery.

c. Record the number of cycles on a cumulative basis plus maintenance and repair information. Note any irregularities. The use of a “Battery Cycle and Main- tenance Record” form such as shown in Figure 2-6 is recommended. If variations in specific gravity readings exceed 20 points (.020) and on-charge voltage, after an equalizing charge, varies by more than .15 volts, contact the manufacturer's service representative. d. When the battery is new, and on at least an annual basis thereafter, read and record the specific gravity and open circuit voltage for all cells of the battery.