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How to take readings of Exide Plante type station battery cells regularly and

during periodic testing? Draft Suggestions along with other general comments.

1. Overall float voltage shall be measured at battery terminals. This may be
done by maintenance staff with an accurate digital multimeter. Normally, Exide
type battery cell shall have float voltage 2.23 to 2.27 Volt per cell. This
means for a 110V battery total voltage shall be between 122.65 to 124.85 V. For
220V, this shall be 245.3V to 249.7V.
2. Two pilot cells shall be selected by operator on each day for taking voltage
and specific gravity for 110V battery and 4 pilot cells shall be for 220V
battery. This will help to cover all cells within one month. The float voltage
thus measured per each pilot cell shall be between 2.23V to 2.27V for both 110V
and 220V battery. Any value outside this range shall be reported by operator to
maintenance staff. Direction shall be given to operators for informing about
abnormal conditions.
3. Electrolyte level of each pilot cell shall be observed and recorded by
operator. One column for recording electrolyte level shall be incorporated in
the log sheet along with voltage and specific gravity readings. Electrolyte
level shall be preferably just below the upper level marking. If the level is
found falling by operator, the same shall be reported to maintenance staff.
1. Switch off the charger and take voltage and specific gravity of all battery
2. The electrolyte level shall not be allowed fall below minimum level. (This
may be marked as red mark). Therefore topping up may be done whenever required.
This may be done by maintenance staff as per the information obtained from
operator. After topping up by distilled water, battery float voltage shall be
increased to 2.3V per cell, that is, 126.5V for 110V battery and 253V for 220V
battery for about half an hour. This is for mixing up the water with
electrolyte. Constant monitoring of cells shall be there during this period.
Voltage shall not be increased excessively. Voltage shall be returned to normal
float value after half hour.
3. Inspect whether there is any sediment collected in the bottom side of each
4. Specific gravity of electrolyte of fully charged cell is 1.195 to 1.205 at 27
degree centigrade. Specific gravity reading shall be corrected according to
temperature variation. Rule is 0.0007 increase with increase in every 1 degree
centigrade above 27 degree centigrade and vice versa.
If the specific gravity of any cell goes below 1.180, equalizing charging is
to be carried out:
Method:- Put the charger in Equalising/boosting manual mode. Charge battery
with a current of 3 percent of rated AH for 24 hours. For example, for 100AH
battery, the current will be 3A. This method may be extended to 48 hours, if
Following points shall be noted while carrying out equalizing charging:
i. Voltage of any cell shall not be increased beyond 2.4V (maximum allowed is
2.45V). Keep the charging current accordingly.
ii. It is generally recommended to carry out equalizing charging with 3 percent

of AH for 24 hours once in a year periodically.

Once in 5 years (at least):
If two battery and charger sets are available, One battery can be taken out for
carrying out discharge test.
Method: Carry out discharge test with the help of a suitable discharge kit.
Discharge at a rate of 10 percent of rated AH. For example, for 100AH battery
this becomes 10A. Continue discharging for 10 hours. Discharging shall be
stopped if voltage of any of battery cell goes below 1.85V. This cells are to be
treated as weak ones and corrective actions to be taken.
After completing discharge test, battery shall be charged as early as
possible. Different methods have been found for charging:
i. Charge with a current 10 percent of rated AH for 15 hours. For example,
100AH battery shall be charged with 10A for a duration of 15 hours. Maximum
charging voltage per cell shall be 2.75V. Temperature shall not be exceeded 45
degrees. If it exceeds, charging shall be stopped to cool down. Charging shall
be resumed and shall be kept for the duration to compensate discharge condition.
ii. The charging to start at the starting rate as mentioned in the product
catalogue for the respective size till the cell voltage reached 2.36 volts per
cell followed by charging at finishing rate pertaining to the specific size
of the battery as mentioned in manufacturers catalogue. The charging to be
stopped when the cell voltage and specific gravity readings are constant for
four consecutive half hourly readings. The expected end-of-charge voltage is of
the order of 2.7 2.75 volts per cell. During charging it has to be ensured
that a minimum Ah input of 125% of the previous discharged Ah is administered to
the battery. The temperature during charging should not increase beyond 45
degree centigrade. In such cases, the charging to be stopped and the cells to
be allowed to cool down till 40 degree centigrade when the charging can be
resumed. The timings are to be noted so that the duration of charge can be
compensated accordingly to ensure that the minimum Ah input requirement is
Recommendaton: If you are doing discharge test for the first time in the
station, it is recommended to carry out with the help of manufacturer.
1. Keep the battery room well ventilated so that the electrolyte temperature at
maximum atmospheric temperature does not exceed 38 degree centigrade.
2. Keep the battery room well lit through out day and night. Windows may be
provided for this. But sun light shall not be allowed to fall directly to
battery. If windows are not possible, artificial lighting shall be made.
3. Exhaust fans shall be ensured in ON condition during equalizing or boost
charging periods.
4. The preferred operating temperature of battery is between 20 to 35 degree.
5. It is to be made sure that an instruction display board is hung in the room
at a well attentive place.
6. Never smoke or do anything which may cause sparking inside battery room
during charging.
7. Never keep float or boost voltage of any cell more than 2.45V and never let
the voltage of any cell less than 1.85V. Charging current of battery shall never
exceed 12 percent of rated AH.
8. Preferred requirement of Charger is:
a. The charger shall be able to supply up to 3V per cell.
b. The charger shall be able to supply current up to 12 percent of rated AH.

The above procedures may be adopted unless the station battery in any station is
maintained by manufacturers recommendations other than this. This procedure is
prepared based on Exide manufacturers recommendations.
Yours faithfully,