User's Manual

ManualsBrandsIronclad ManualsAutomobile PartsIronclad Section 28.00

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

Summary of content (11 pages)

PAGE 1
Section 28.
PAGE 2
3. Be especially careful when working on battery terminal connections. Do not connect any two or more terminals together unless the connection is a proper and correct electrical one. The threshold planning quantity (TPQ) for sulfuric acid is 1,000 pounds. c. Recycling: 1. Spent lead-acid batteries which are destined for recycling are not regulated under federal hazardous waste regulations or by most state regulations. Contact your state environmental agency for additional information. d.
PAGE 3
5. CONSTRUCTION what you know about a battery’s volts, amps, and ampere-hours, you’re ready to easily change those numbers into the final key concept, watts. Fig. 2 illustrates the construction of a typical motive power cell of the tubular design. Watt, W.: Using battery voltage or amperage alone doesn’t tell you enough about the battery. Multiplying those two values together does. The answer you get is a battery’s wattage: the electrical power a battery can provide.
PAGE 4
. Give the battery an equalizing charge but keep resetting the charger to the equalize position until the specific gravities remain constant for a period of three hours. At no time should battery temperature be allowed to exceed 110°F (43°C). 5. At the completion of the charge, the specific gravities of all cells corrected to 77°F (25°C) should be as specified on the battery nameplate or shown in Table 3.
PAGE 5
In sub-freezing temperatures, water should be added just before charging is completed to insure prompt mixing with the electrolyte. Otherwise it may freeze on the surface before mixing. No permanent harm results from low temperature operation as long as freezing is avoided. d. As mentioned, a battery should not be discharged beyond the point where the cells approach exhaustion. This is referred to as “overdischarging” and can have very harmful results, particularly if repeated for several days or cycles.
PAGE 6
14. CHARGING CHARACTERISTICS e. When charging batteries while they are in the vehicle, assure proper ventilation and follow the manufacturers instructions. Open the battery cover, if so equipped, as well as the battery compartment cover of the vehicle. Not following these recommendations can cause gaspockets to remain in the vehicle or battery giving rise to possible explosions when the vehicle is put into use. a. Only EnerSys approved charging methods should be used.
PAGE 7
16. DETERMINATION OF CAPACITY c. Since the average motive power battery passes a “test” every day by performing its regular work, it is seldom necessary to conduct a formal test of its capacity. Also, most users do not have the facilities to do this conveniently or accurately. If any such testing is desired, consult your EnerSys Representative regarding equipment and procedure. a. A battery's capacity will, of course, decrease toward the end of its life.
PAGE 8
e. Another convenient way to ensure proper fill levels is the use of a single point watering (SPW) system. The EnerSys Battery Irrigation System or EZ Fill System are effecient methods of watering a battery. These reliable quality systems allow the operator to fill to the proper level each and every time. #853638 may help remove these harmful deposits. c. To both clean and neutralize your battery use EnerSys PRO Wash Cleaner/Neutralizer #94883.
PAGE 9
NOTE: Specific gravity changes with temperature. Normal values are at 77°F . This should be kept in mind when reading specific gravity and proper correction should be made to judge normal values. For each 3° above 77°F ADD 0.001 to the measured Sp. Gr. For each 3° below 77°F SUBTRACT 0.001. 21. STORAGE OF BATTERIES a. Batteries should be stored in a clean, cool, dry and well ventilated location away from radiators or heating ducts, etc., and protected from exposure to direct sunlight. b.
PAGE 10
SERVICE TOOLS 0*1. *02. *03. 0*4. CELL LIFTER - Belt type cat. #SS-5746 CROSS LINK PUDDLING DAM - cat. #SS-5749 CABLE LUG PUDDLING DAM - cat. #SS-5747 CONNECTOR PUDDLING DAM - cat. #SS-5745 (2 hole) *05. CONNECTOR PUDDLING DAM - cat. #SS-5745-1 (4 hole) *06. CONNECTOR PUDDLING DAM - cat. #SS-5745-2 (4 hole) *07. CONNECTOR PUDDLING DAM - cat. #SS-5745-3 (4 hole) *08. POST BURNING RING DAM - cat. #SA-60485 *09. BURNING DAM - cat. #SS-60321 *10. TOTE WELD OUTFIT - cat. #TW840-4474 *11.
PAGE 11
™ ISO 9000 ™ Section 28.00 Rev. H 11/06 © 2006 EnerSys All Rights Reserved. Trademarks are the property of EnerSys and its affiliates unless otherwise noted. Grafika 2366 Bernville Road, Reading, PA 19605 1-800-EnerSys www.enersysmp.com mpe@enersys.