Procedure for Acceptance and Performance Testing of Absolyte Batteries

1. Initial Conditions
a). b.) c). d). e). f). g). Verify that the battery has had an equalizing charge completed more than 3 days and less than 30 days prior to the start of the test (see attached procedure). Check all battery connections and make sure that all connectors are clean, tight, and free of corrosion. Read and record the float voltage of each cell just prior to the test. Read and record the temperature of the battery cell for an average battery temperature (suggested 10% of cells). Read and record the battery terminal float voltage. Disconnect the charger from the battery. Take adequate precautions (such as isolating the battery to be tested from other batteries and critical loads) to ensure that a failure will not jeopardize other systems or equipment.

2.

Test Length
The recommended procedure is to make a capacity test for approximately the same length of time as the critical period for which the battery is sized.

3.

Test Discharge Rate

For the test using a DC load bank, the discharge rate should be a constant current load equal to the manufacturers rating of the battery for the selected test length. Note that the test discharge current is equal to the rated discharge current divided by K, where K is the discharge current correction factor for the initial cell temperature (see attached table).
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4.

Acceptance Test
Set up a load with an ammeter and a voltmeter with the provisions that the load be varied to maintain a constant current discharge equal to the selected rate from above. a). b). Connect the load to the battery, start the timing, and continue to maintain the selected discharge rate. Maintain the discharge rate until the battery terminal voltage decreases to a value equal to the specified average voltage per cell times the number of cells. For example, in the case of a 60 cell battery with a specified end voltage of 1.75 volts per cell (VPC), the end terminal voltage will be 105 VDC (60 cells x 1.75 end volts per cell = 105 VDC). Read and record individual cell voltages and the battery terminal voltage. The readings should be taken while the load is applied at the beginning and the completion of the test and at 30 to 60 minute intervals (dependent on specified test length) followed by 15 minute intervals for the last hour. If an individual cell is approaching reversal of its polarity (0.00 V) but the terminal voltage has not yet reached its test limit, the test should be continued with a jumper across the weak cell. Complete the jumper connection away from the cell to avoid arcing near the cell. The new minimum terminal voltage should be determined based on the remaining cells. Observe the battery for inter-cell connector heating. At the conclusion of the test, determine the battery capacity according to the following procedure.

c).

d).

e). f).

5.

Determining Battery Capacity

To determine the battery capacity, use the following equation: % Capacity at 25 C = (Ta / Ts) x 100 where Ta = actual time of test to specified terminal voltage. Ts = rated time to specified terminal voltage.
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6.

Restoration
Disconnect all test apparatus. Recharge battery and return to normal service.

7.

Battery Replacement Criteria

The recommended practice is to replace the battery if its capacity as determined by the above equation is below 80% of the manufacturers rating. Note that low individual cell voltages are not a concern as long as the terminal voltage remains at or above the specified end voltage. As a rule of thumb, individual cells having an end voltage of more than a 0.30 VPC below the specified end voltage should be considered for replacement (i.e., 1.45 VPC for a test end voltage of 1.75 VPC).

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Equalizing Charge Method

Constant voltage charging is the method for giving an equalizing charge. Determine the maximum voltage that may be applied to the system equipment. This voltage, divided by the number of cells connected in series, will establish the maximum volts per cell that may be used to perform the equalizing charge in the shortest period of time (not to exceed 2.35 VPC applicable at 25 C). Recommended voltages and times are as follows: Cell Volts 2.30 VPC 2.35 VPC Time 24 hours 12 hours

Note: Charge volt listed above are for 25 C. For other temperatures, a compensation factor of 0.0055 V/ C per cell is recommended. The minimum voltage is 2.20 VPC. The maximum voltage is 2.35 VPC. Temperature correction does not apply outside this range. V corrected = V at 25 C ((Temp. actual - 25 C) x (0.0055 V/ C)) Raise the voltage to the maximum value permitted as described above. When charging current has tapered and stabilized (no further reduction for 3 hours), charge for the # of hours shown above or until the lowest cell voltage ceases to rise. Monitoring of cell voltages should be started during the final 10% of the applicable time period to determine the lowest cell in the battery.

Exide Technologies Indust. Energy Division Middle East Office PO Box 74298 Dubai United Arab Emirates Tel.: + 971 4 343 7420 Fax: + 971 4 343 7410