CHARGING METHOD AND EQUIPMENT:

Correct charging procedure is most important to ensure satisfactory battery life

and performance. Modern charging equipment, most of which uses AC Supply,
provides safe and flexible control of battery charging either automatically or with
the minimum of manual attention.
Charging Principle:
A storage battery cannot supply electrical energy unless passing Direct Current
through them has previously activated the plates. In dry and uncharged battery,
after adding dilute sulphuric acid and before putting it in service, it is essential to
give the battery an initial Charge.
Initial Charge:
The initial charge consists in passing a current into the battery for a number of
hours as recommended by the battery makers. It is very important that the
instructions regarding initial charge be closed followed, as this charge service to
complete starts its life in the best possible condition so that it is capable of giving
rated capacity and satisfactory performance from the moment it goes into
service.

The following care to be taken prior to and during initial

charging:
1) Unpacking/Handling.
2) Battery Charging Room.
3) Power Requirement.
4) Polarity of Charging Leads.
5) Sulphuric Acid.
Caution.
(a) Vessels:
(b) Protective Wear :
(c) Acid Splashes :
(d)NEVER ADD WATER TO CONCENTRATE ACID, IT WILL
SPURT DANGEROUSLY.

1. Filling the Cells.

2.Electrolyte Temperature during charge.
3. Completion of Charge.
i) Constant Specific Gravity.
ii) Constant Voltage.
iii) Free Gassing.
4. Records.
5. Adjustment Of Service Sp. Gravity

6. Adjust the level.

7. Wipe the cells clean and dry & Renew Petroleum

Jelly.
8. Charging is service.:
A battery once it has supplied electrical energy can be
restored to the charged condition only by passing direct
current into it in correct direction.
The addition of Sulphuric Acid or patent dopes to a
discharged battery cannot replace the electrical energy
supplied by the battery.
Correct charging is an important to batteries as correct
feeding is to human beings in either case a deficiency or
surfeit will eventually be well balanced i.e. if you take out
100Ah, you will have to feed in 115Ah. It is also obvious that
the charging methods will be varied as per duty performed
by the battery.

Equalising Charge:
To ensure that every cell of a battery is maintained in a healthy
condition so that maximum life is obtained, it is advisable to give an
extended charge every two to three months. The extra charge should
be given at a low rate shown in the battery makers catalogue or a
rate between three & five Amps per 100Ah. Capacity. Equqlising
Charge for 12 hours always follows a normal bench charge until
again at low ampere every cell is gassing freely and the reading of
voltage and specific gravity has ceased to rise. It is also advisable to
record cell voltage, specific gravity and electrolyte temperature of all
cells which may help to guide regarding health of the cells/battery.
No special skill is required in taking cell reading and a little practice in
using hydrometer, voltmeter, thermometer and all that is required.
If required to boost charge at higher amps then maximum 2.5 times of
the normal rate of charge can be given for quick charge in short
period. But it is important to lower the amps to normal rate as soon as
the voltage per cell has raised to 2.35 volts per cell.

Care for battery in service :

It is important that naked flames are kept away from the cells at
all the times and articles, especially metallic ones not be allowed
near cells.
All parts of the battery should be regularly wiped clean and dry
and the runners and all exposed metal work well coated with
Petroleum Jelly.
Should there be any corrosion products, neutralised any
remaining acid with washing soda solution or ammonia and
project the part from further corrosion by covering with Petroleum
Jelly.
It is a good rule to add distilled water regularly even through the
battery may not require toping up immediately. Nothing but
distilled water should be used. Top up to the correct level or if in
doubt, under top, to avoid acid overflowing from the cells when
gassing on charging.

GIST OF INITIAL CHARGING OF LEAD ACID

CELL/ BATTERIES:
1. On receipt of dry and uncharged cells/units,
clean then either with air blower or with tap
water keeping the vent plugs and other plugs
tightly closed.
2. Physically check for any damages.
3. Arrange/place the cells on charging bay. Mind
+ve and ve terminals are in proper position.
4. Fill in with recommended specific gravity, Cool
and pure battery grade Sulphuric acid up to
recommended level. Do not over fill acid.

GIST OF INITIAL CHARGING (Continued):

5.Check polarity of all cell by using 3-0-3
Voltmeter Or A Multi-Meter.
6.Allow a rest for 12 to 24 hours. Top up again
with acid up to maximum recommended level.
7.Rearrange the cell /cells/ if found polarity in
reverse direction.
8.Connected
connectors.

all

the

inter

9. Start
charging
with
recommended current.

cell/inter

unit

manufacturers

GIST OF INITIAL CHARGING (Continued):

10. Keep records ( Sp. Gravity, Voltage and Electrolyte
temperature ) of pilot cells ( Choose one pilot cell for
every 15 cells ), for every hour.
11. Record specific gravity, voltage and electrolyte
temperature of each cell for every 4 hours.
12. Continue charging as per manufacturers instruction.
13. Check the symptoms for completion of charging i.e.
a) Free gassing b) Voltage reaching 2.75 volt per cell
and remains constant for 5-6 hours. c) Sp. Gravity
remains constant for 5 to 6 hours.
14. Adjust specific gravity to a working level as
recommended by adding of distilled water (
conforming to IS 1069 ) or by adding higher specific
gravity electrolyte if required.

GIST OF INITIAL CHARGING (Continued):

15. Continue charging during adjustment of specific
gravity.
16. Allow a rest for 12 hours.
17. Discharge the battery C10 upto end voltage of 1.85
volt/cell.
18. Recharge immediately
recommended rate.

after

discharging

in

Normal Failure Mode & Cause Of Lead Acid Cells:

1. Sulphation:

a) Over Charge.
b) Allowing A Battery/Cell To Stand Idle.
c) Starvation.
d) Allowing Electrolyte To Fall Below Top Of Plates.
e) Impurities i) Impurities Which Merely Causes self Discharge.
ii) Impurities Which Attack The Plates.
d) Adding Acid Instead Of Water.

2. Buckling Of Plates: a) Over Discharge.

b) Continued Operation With Battery In Discharge
Condition (Starved Condition).
c) Charging At High Rates.
d) Non-Uniform Distribution Of Current Over The Plates.
e) Defective Grid Alloy.

Normal Failure Mode & Cause Of Lead Acid Cells:

3. Shedding Or Loss OF Active Materials:
a) Normal Shedding.
b) Excessive Charging Rate Or Overcharging.
c) Charging Sulphated Plates at Very High Rate.
d) Charging Only A Part Of The Plate.
e) Freezing.
4. Container Failure:
a) Improper Curing Of Hard Rubber Containers.
b) Improper Heat Sealing Of PP Batteries.
c) Rough Handling.
d) Any Other Heavy Materials Kept On Batteries Or
Stacked At More Than Permissible Layers.
e) Explosion In Cell.

Normal Failure Mode & Cause Of Lead Acid Cells:

5. Terminal / Connectors Corrosion:
a) Too Much Water Added.
b) No Renewal Of Petroleum Jelly.
c) Battery Not Installed properly.
d) Poor Sealing Of Batteries / Cells.
e) Vent Plugs Loose
f) Electrolyte Spillage On Top Of Cells Due To Careless
Checking Of Sp. Gravity, Droplets Of Acid On Top.
g) Battery Cable / Connectors Loose.
h) Attaching Wires Directly To Battery Terminals.
6. Loss Of capacity:

a) Impurity In Electrolyte.
b) Sulphation.
c) Loose Active Materials.
d) Incorrect Proportion Of Electrolyte / Water.
e) Separators Pores Clogged.
f) Shedding.
g) Low Level Electrolyte.
h) Effect Of Age.

Normal Failure Mode & Cause Of Lead Acid Cells:

7. Short Circuit:

a) Worn Out Separators

b) Foreign Materials In Cell.
c) Lead Run In Cell.
d) Accumulation Of Mud Space With Active
Materials Due To Excessive Shedding.
e) Treeing In Cells Due To Poor Maintenance.

8. Reversal Of Plates.
9. Earth Leakage In Battery bank.
10. Electrolyte Trouble: a) High Sp. Gravity Electrolyte.
b) Low Sp. Gravity Electrolyte.
c) High Level Of Electrolyte.
d) Low Level Of Electrolyte

Care of battery out of service :

If the battery is used at irregular intervals, give it a
bench charge every month and keep in open circuit in
a cool and dry place. Every month the electrolyte level
should be checked. The electrolyte level should be
checked and battery charged fully before it is put back
into service.