INSTRUCTIONS FOR INSTALLATION,
OPERATION, AND MAINTENANCE OF
LEAD-ACID BATTERIES IN MOTIVE POWER
SERVICE
Section 28.00
Instructions for Installation,
Operation, and Maintenance of
Lead-Acid Batteries in
Motive 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
6
DRY CHARGED BATTERIES
7
INSTALLATION OF THE BATTERY
8
FAST CHARGING AND OPPORTUNITY CHARGING
9
OPERATION
10
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
22
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. Avoid spilling acid.
3. PRO WASH
TM
neutralizing and cleaning solution or
bicarbonate of soda solution (one pound to a gallon
water) will neutralize any acid accidentally spilled. Apply
the PRO Wash 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
TM
