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INSTRUCTIONS FOR INSTALLATION,

OPERATION, AND MAINTENANCE OF

LEAD-ACID BATTERIES IN MOTIVE POWER

SERVICE

Section 28.00

nstructions for Installation,

Operation, and Maintenance of

Lead-Acid Batteries in

otive Power Service

TABLE OF CONTENTS

SECTION

SAFETY PRECAUTIONS 1

SPILLS AND RECYCLING 2

INTRODUCTION 3

FUNDAMENTALS OF A STORAGE BATTERY 4

CONSTRUCTION 5

INSPECTION OF BATTERY UPON RECEIPT

DRY CHARGED BATTERIES 7

INSTALLATION OF THE BATTERY 8

FAST CHARGING AND OPPORTUNITY CHARGING 9

OPERATION

TEMPERATURES 11

DISCHARGE CHARACTERISTICS 12

CHARGING EQUIPMENT 13

CHARGING CHARACTERISTICS 14

MAINTENANCE AND RECORDS 15

DETERMINATION OF CAPACITY 16

TROUBLESHOOTING 17

WATERING 18

CLEANING 19

ADJUSTING SPECIFIC GRAVITIES 20

STORAGE OF BATTERIES 21

ACCESSORIES

TOOLS 23

1. SAFETY PRECAUTIONS

a. Explosion can result from the gases produced by a

battery:

1. Do not smoke, use an open flame, or create arcs or

sparks in the vicinity of a battery

2. Only charge a battery in a well-ventilated area with

the cover of battery or compartment raised for maximum

ventilation.

3. Do not charge the battery at a current greater than

5 amps per 100 amp-hours capacity at the end of charge.

4. Every battery gives off hydrogen and oxygen during

recharge. Most of the gassing occurs after the 80%

point has been reached. As the breakdown of water

occurs oxygen and hydrogen are produced. The

concentration of the gasses is proportional to the current

being delivered to the battery.

To calculate the hydrogen produced use the following

formula, and ventilate the area as required. Hydrogen

must be ventilated in order to avoid an explosion.

Hydrogen concentrations of 4% or greater will cause an

explosion. When calculating assume all chargers in finish

rate at same time.

The National Fire Protection Association (NFPA) allows

up to 1% concentration. Make sure the ventilation system

can remove the hydrogen before it reaches

concentrations of 1% within the charging area.

Formula

0.00027 x (finish rate) x (number of cells) = cu. ft. of

hydrogen produced per min.

5. The ventilation system must also be designed to provide

removal of hydrogen and excess heat from the area directly

above charging batteries. Inlet air ducts should be placed

at shoulder height or lower so as to provide air movement

across the charging room and across batteries. Failure to

properly ventilate charging areas may result in employee

complaints of heat and “battery odor”.

b. Severe burns can be caused by the sulfuric acid contained

in the batteries covered by these instructions:

1. Do not get acid in eyes, on skin or clothing. In case of

contact, flush immediately and thoroughly with clean

water for at least 15 minutes. Obtain medical attention when

eyes are affected.

2. In handling sulfuric acid, wear a face shield, plastic or

rubber apron, and gloves.

void spilling acid.

3. PRO W

neutralizing and cleaning solution or

bicarbonate of soda solution (one pound to a gallon

water) will neutralize any acid accidentally spilled. Apply

the PRO W

ash solution until it turns yellow (bicarbonate

of soda solution stops bubbling), then rinse with clear

water. Do not allow any of this solution to enter the cells.

When diluting concentrated acid, always add acid to

water, never vice versa. Pour slowly and stir constantly,

to avoid excessive heat or violent chemical reaction.

4. Batteries and sulfuric acid should be handled only by

persons who have been instructed on the potential

chemical hazards, in accordance with the OSHA

29 C.F

.R.

1910.1200, Hazard Communication Standard. Refer to

EnerSys Material Safety Data Sheet (MSDS) for

lead-acid batteries.

c. The battery is electrically live at all times:

1. Keep the top of the battery clean and dry to prevent

ground shorts and corrosion.

2. Do not lay metallic objects on the battery; insulate all

tools used in working on the battery to prevent short circuits.

Also remove all jewelry before working on the battery

TUBULAR SINCE 1910

1 2 3 4 5 6 ... 10 11

Sommario

Pagina 1 - OPERATION, AND MAINTENANCE OF

INSTRUCTIONS FOR INSTALLATION,OPERATION, AND MAINTENANCE OFLEAD-ACID BATTERIES IN MOTIVE POWERSERVICESection 28.00Instructions for Installation,Operat

Pagina 2 - 4. FUNDAMENTALS

SERVICE TOOLS0*1. CELL LIFTER - Belt type cat. #SS-5746*02. CROSS LINK PUDDLING DAM - cat. #SS-5749*03. CABLE LUG PUDDLING DAM - cat. #SS-57470*4. CON

Pagina 3 - BATTERIES

Pagina 4 - CHARGING PROCEDURES

3. Be especially careful when working on batteryterminal connections. Do not connect any two or moreterminals together unless the connection is a prop

Pagina 5 - 13. CHARGING EQUIPMENT

what you know about a battery’s volts, amps, and ampere-hours,you’re ready to easily change those numbers into the final keyconcept, watts.Watt,W.: Us

Pagina 6 - 15. MAINTENANCE AND

4. Give the battery an equalizing charge but keep resettingthe charger to the equalize position until the specific gravitiesremain constant for a per

Pagina 7 - 17. TROUBLESHOOTING

In sub-freezing temperatures, water should be added justbefore charging is completed to insure prompt mixingwith the electrolyte. Otherwise it may fre

Pagina 8 - VENT WELL

14. CHARGINGCHARACTERISTICSa. Only EnerSys approved charging methods should beused. To maximize life, charging should not result inexcessive gassing

Pagina 9 - OTHER OPTIONAL ACCESSORIES:

16. DETERMINATION OFCAPACITYa. A battery's capacity will, of course, decrease toward theend of its life. Assuming no specific cause of trouble,

Pagina 10

e. Another convenient way to ensure proper fill levels is theuse of a single point watering (SPW) system. The EnerSysBattery Irrigation System or EZ

Pagina 11

i. EnerSys Pro-Meter #94870. This shirt pocket sizedmeter is versatile for 13 ranges in AC, DC and OHM readings.It has an audible continuity signal an

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