Nickel CadmiumBATTERIESPOCKET PLATESTATIONARY BATTERIESINSTALLATION and OPERATINGINSTRUCTIONSSupplied World ide !"#SEC Indu$%rial Ba%%er" Co&Last Revised July 2005TABLE O' CONTENTSSECTIONCONTENTPAGESECTIONCONTENTPAGE1.0Per$onal Sa(e%" In(orma%ion35.4Cells Supplied Unfilled and1.1Battery Safety Information3Deep Discharged

!.0S%ora)e3".0*ain%enance in Ser+ice

!.1Unpac#ing3".1$outine %aintenance

!.!Storage3".!%aintenance &ools

".3'lectrolyte

3.0Commi$$ionin)4".4&a#ing Specific (ra)ity $eading*3.1mi+ing of Dry 'lectrolyte4".5&opping Up*3.!%i+ing ,essel4"."Cleaning the Battery*3.3%i+ing of 'lectrolyte5".-'lectrolyte Changes*3.4.illing the Cells5-.0Te$% Procedure$104.0General In$%alla%ion In(orma%ion "-.1Determination of /01 and /!C03104.1Steel Case Cells-in the 'lectrolyte4.!2lastic Cells--.1.1%a#ing 1 3 1CI105.0Commi$$ionin) C,ar)e--.1.!Determining the /!C03 Content10-.1.3Determining the 'lectrolyte5.1&ype of Charger-Density115.!Cells Supplied .illed and--.!Determination of /01 and /!C0chargedin the 'lectrolyte5.3Cells Supplied .illed and4 5lternati)e %ethod11Discharged

.0Battery %aintenance $egister1!*.0&echnical Support1310.0Battery $eport142SECTION -. PERSONAL SA'ETY IN'OR*ATIONWARNING . 'OR YOUR /EALT/ AN0 SA'ETY5l6ays 6ear goggles and ru77er glo)es and prefera7ly protecti)e clothing 6hen 6or#ing on the 7attery or electrolyte. $emem7er that the 7attery electrolyte is corrosi)e al#aline potassium hydro+ide.Before 6or#ing on the 7attery8 chec# that ade9uate supplies of clean cold 6ater and saline solution are a)aila7le. Saline solution should 7e #ept in a s9uee:y 7ottle suita7le for irrigating the eyes. In the e)ent of contact 6ith electrolyte8 the affected s#in should 7e 6ashed 6ith copious amounts of clean cold 6ater. If electrolyte enters the eyes8 they should 7e held open and irrigated 6ith saline solutionand then doused li7erally 6ith clean cold 6ater. In allcases immediately o7tain medical attention.3e)er permit smo#ing8 spar#s or any #ind of flame near the 7attery8 6hether filled or empty8 charged or discharged. $emem7er that 7attery cells may contain e+plosi)e gasses.$emem7er that the 7attery is electrically li)e at all times and cannot 7e isolated in the con)entional sense8 although )oltage at any point can 7e reduced 7y remo)al of appropriate intercell connectors. Steel cell containers must al6ays 7e considered ;li)eects onto cell terminals. 5l6ays remo)e 6atches and rings 7efore 6or#ing on a 7attery. Ba%%er" Sa(e%" In(orma%ion WARNING . 'OR T/E BATTERY1S /EALT/ AN0 SA'ETY 5 7attery is normally the last line of defence against disaster. %aintenance should reflect the fact that li)es may depend on its operation under emergency conditions. If in dou7t contact S'C Industrial Battery Co. ?imited. 5dd only purified 6ater @distilled or deioni:edA8 6hen topping up the 7attery. 3e)er add any #ind of electrolyte or conditioner e+cept under direct instruction from S'C Industrial Battery co. ?imited. Store and operate nic#el cadmium 7atteries separatefrom lead acid 7atteries. 3e)er 6or# on a 7attery 6ith tools8 6hich ha)e pre)iously 7een used on a lead acid 7attery8 this 6ill destroy an al#aline 3ic#el Cadmium 7attery. /eep the 7attery clean and correctly filled. Chec# that connections are correctly tor9ued. M 5 bolt4.0 N-m35in-lbs.M10 bolt7.0 N-m62 in-lbM16 bolt11.3 N-m100 in-lb)M20 bolt25.0 N-m220 in-lb.'nsure the charger is maintaining the 7attery at the recommended )oltage. 3ic#el cadmium poc#et plate 7atteries operate at their optimum le)el 6hen gi)en regular e9uali:ing charges. 5ll S'C nic#el cadmium 7atteries should 7esu7>ected to an e9uali:ing charge e)ery " months. 2eriodically @appro+. e)ery !4 4 3" monthsA send a small sample @!0 mlA of electrolyte for analysis of potassium car7onate content. S'C Industrial Battery Co. ?imited can arrange to carry out this analysis for you on re9uest. Carefully e+amine the consignment for signs of damage or loss of electrolyte8 6hich may ha)e occurred in transit. If any damage is e)ident8 ad)ise the carriers immediately in 6riting and send a copy of the letter to S'C Industrial Battery Co. ?imited. Bithin 14 days of arri)al ma#e sure that the consignment is complete and agrees 6ith the pac#ing list included.Do not discard any accessories 6ith the pac#ing material.&he filling holes in the cell lids 6ill 7e sealed 6ith special transit plugs8 6hich should 7e left in position until the 7attery is ready to 7e put into ser)ice. If cellsha)e 7een supplied filled8 chec# the electrolyte le)el in all cells. 57normally lo6 le)els8 i.e. 7elo6 the minimum le)el8 should 7e reported to S'C Industrial Battery Co. ?imited immediately8 and to the carrier if there is an e)idence of loss of electrolyte in transit.SECTION 2Unpackin) Carefully e+amine the consignment for signs of damage or loss of electrolyte8 6hich may ha)e occurred during transit. If any damage is e)ident8 ad)ise the carriers immediately in 6riting and send a copy of the letter to S'C Industrial Battery Co. ?imited.Damaged cells contain al#aline electrolyte and acti)ematerials of nic#el cadmium and their compounds. &he acti)e materials may only 7e e+posed if a cell container is 7ro#en. If they are e+posed they may e)ol)e heat and could initiate a fire.3ic#el and Cadmium are classified to+ic respecti)ely harmful and should 7e treated accordingly. 5ny acti)e material should 7e #ept damp and filled into a suita7ly la7eled al#aline resistant container prior to disposal.Strict personal safety should 7e o7ser)ed at all times.S%ora)e &he period for 6hich S'C 3ic#el Cadmium cells can 7e stored depends on the condition in 6hich they areordered and supplied.Cells supplied filled and charged may 7e stored for ama+imum of " months @3 months in tropical climatesAfrom date of desptach from the factory. If8 for una)oida7le reasons8 cells must 7e stored longer than this8 then eitherC Cells must 7e gi)en a commissioning charge e)ery "@3A months and again prior to commissioning. 'lectrolyte le)els must 7e chec#ed at the end of the charge and ifnecessary8 restoredto the correctle)el7y the addition of distilled 6ater. ....... 0$Cells must 7e gi)en a commissioning charge8 electrolyte ad>usted to the correct le)el8 then discharged at a lo6 current8 i.e. not greater than a current in amps e9ual to 10D of the cells C5 capacity8 until the terminal )oltage of e)ery cell is less than 1.0 )olts. 5fter refitting transit plugs8 the cells may 7e stored for 1! months8 7efore the process is repeated. Bhen commissioning cells stored in this 6ay8 a cycle of commissioning charge= discharge should 7e carried out8 follo6ed 7y a commissioning charge. 0$.... Cells must 7e gi)en a commissioning charge then discharge at a lo6 current as @BA 7ut continued to 0.0)olts. 'lectrolyte should then 7e drained from each cell 7y in)erting the cell o)er a suita7le container for a7out 5 minutes. &his electrolyte must not 7e used again. 5fter refitting transit plugs8 cells in this condition may 7e stored indefinitely 6ithout further treatment. Bhen commissioning8 cells must 7e filled 6ith ne6 electrolyte and gi)en a cycle of commissioning charge=discharge as in @BA8 then 6hen finally recharged8 the cells may 7e put into ser)ice. Cells supplied filled and discharged may 7e stored under the same condition as @BA8 or for e+tended storage should recei)e the procedure as @CA. Cells supplied discharged and drained may 7e stored indefinitely. Dry electrolyte supplied for discharged and drained cells must 7e #ept dry at all times in airtight containers.2rior to any period of storage8 the e+terior of cells should 7e cleaned and dried and any 7right metal parts coated 6ith petroleum >elly.If cells are to 7e stored filled8 then electrolyte le)els should 7e ad>usted to6ards the end of a period of charge 6hen cells are gassing. &his is to allo6 mi+ing of any distilled 6ater8 6hich may 7e added8 thus reducing the possi7ility of the pure 6ater free:ing in storage.&ransit plugs should 7e remo)ed during charging 7utmust 7e replaced prior to the cells 7eing stored.Cells should 7e stored in sealed8 polyethylene 7ags 6ith silica gel desiccant8 in a clean dry area and should not 7e su7>ected to temperatures normally outside the range of 0C to 40C.'lectrolyte is corrosi)e and proper arrangements should 7e made for its disposal if emptied from cells. If re9uired8 and pro)ided that the material is deli)ered to us properly pac#ed in suita7le containers8 S'C Industrial Battery Co. ?imited 6ill underta#e to process the 6aste material for a nominal charge.SECTION 3Commi$$ionin)*i4in) o( 0r" Elec%rol"%e If cells ha)e 7een supplied and=or stored in a discharged and drained condition8 it 6ill 7e necessary to mi+ a fresh supply of electrolyte. 2ac#ages of dry electrolyte should remain sealed until actually re9uired for use. 0nly distilled 6ater should 7e used for the mi+. 5ppro+imately 3 liters of distilled 6ater 6ill 7e needed for each #g of dry electrolyte. CAUTION# Elec%rol"%e i$ corro$i+e and %,e opera%or *UST ear )o))le$ and ru!!er )lo+e$ and pre(era!l" pro%ec%i+e clo%,in). &he 9uantities of dry electrolyte re9uired for each celltype are sho6n 7elo6. *i4in) 5e$$el &he mi+ing )essel has to 7e a7le to meet t6o re9uirements. .irstly8 it must not contaminate the electrolyte and secondly8 it must 7e a7le to 6ithstandthe considera7le heat generated during the mi+ing process. 2lastic containers8 6hile not li#ely to contaminate theelectrolyte8 are usually una7le to 6ithstand the 40CE heat generated during the mi+ing process and are8 therefore8 unsuita7le. Copper8 aluminum8 any gal)ani:ed or tinned )essels or )essels 6ith soldered >oints 6ill contaminate the electrolyte and therefore must not 7e used. 2lain iron8 steel or stainless steel )essels are ideal pro)iding they are clean and in good condition. &he si:e of the )essels should reasona7ly correspond 6ith the largest si:e of pac# of electrolytesupplied so that the total electrolyte in any pac# may 7e mi+ed at one time. Standard pac# si:es of dry electrolyte are !5#g or asspecified=re9uired 7y customers. Dry electrolyte 6ill 7e supplied for each 7attery ordered in a com7ination of these pac# si:esC 4&otal 9uantity of dry electrolyte%inimum si:e of mi+ing$e9uired for each 7atteryCContainer?ess than 1!F #g!0 liters5 (al.?ess than !5 #g40 liters10 (al.%ore than !5 #g100 liters!5 (al.!LL "#$!N%M &'())R# !L!".*5 R'"!$e+ !LL &,-),L 11$110.077,L 1.$1.0.11.,L 24$240.0/4,L 30$300.0./,L 40$400.211,L 45$450.211,L 55$550.1.5,L 65$650.161,L .0$.00.46/,L 100$1000.441,L 120$1200.42/,L 140$1400.3.5,L 150$1500.530,L 160$1600./.7,L 1.5$1.50...2,L 200$2000...2,L 230$2300.7/4,L 270$2700.70.,L 300$3000.621,L 340$3401.252,L 370$3701.1/2,L 400$4001.132,L 435$4351.072,L 470$4701.012,L 520$5201.7.2,L 560$5601.734,L 600$6001./27,L 650$6503./02,L 740$7403.757,L .40$.403.612,L 1000$10002../0,L 1250$12503.010,L 1500$15003.1/1,M 11$110.077,M 1.$1.0.106,M 24$240.0/4,M 30$300.0./,M 40$400.212,M 4.$4.0.1.5,M 55$550.161,M 65$650.310,M 75$750.2/4,M /0$/00.43.,M 110$1100.37.,M 125$1250.4/6,M 140$1400.434,M 160$1600.../,M 1.5$1.50..21,M 205$2050.6/.,M 225$2250.674,M 250$2500.626,M 270$2701.252,M 300$3001.204,M 320$3201.154,M 340$3401.0.4,M 355$3551.036,M 3.0$3.00./.7,M 400$4000./15,M 450$4501.301,M 520$5201..06,M 600$6003.661,M 675$6753.733,M 750$7503.372,M 1000$10003.46.,M 1250$12504.335,0 10$100.121,0 20$200.0.2,0 30$300.1.6,0 40$400.147,0 50$500.222,0 50$500.3/0,0 65$650.340,0 .0$.00.2./,0 /0$/00.633,0 100$1000.612,0 125$1250.541,0 150$1500..1/,0 1.5$1.51.373,0 200$2001.2/6,0 235$2351.173*i4in) o( Elec%rol"%e CAUTION# W,en ,andlin) elec%rol"%e ala"$ ear e"e pro%ec%ion and ru!!er )lo+e$& Ne+er add a%er %o dr" elec%rol"%e6 ala"$ add dr" elec%rol"%e %oa%er alread" in %,e mi4in) +e$$el. 2our into the mi+ing )essel !43 liters @0.5 (al.A of distilled 6ater for e)ery #g of dry electrolyte to 7e mi+ed. Slo6ly add the dry electrolyte8 stirring all the time 6ith a steel rod. &a#e care not to cause splashes. &he solution 6ill 7ecome )ery hot 7ut should 7e thoroughly mi+ed and then left to cool. Bhile cooling8 co)er the container to a)oid contact 7et6een the electrolyte and air8 ta#ing care that the material of the co)er 6ill not contaminate the electrolyte. Bhen the electrolyte is cool8 measure the S( 6ith a hydrometer and the temperature of the electrolyte 6ith a thermometer. &he reading of the hydrometer should 7e corrected for temperature as follo6sC !L!".123"R'"!L!".'))"!M$.&-) 4R%M"!M$.&5) "%6R!')7N-6R!')7N-0-0.010200.0002-0.00/220.0014-0.00.240.0026-0.007260.003.-0.0062.0.00410-0.005300.00512-0.004320.00614-0.003340.00716-0.002360.00.1.-0.0013.0.00/400.010@.or e+ample8 S( reading of 1.1* is ta#en at an electrolyte temperature of 40C 6hen corrected to !0C is 1.!0 @1.1* E 0.010A.&he corrected S( of the mi+ at this stage 6ill 7e higher than the re9uired 1.1*0=1.!00 and therefore8 a small 9uantity of distilled 6ater should 7e added. 5fter stirring6ell8 ta#e another S( reading and again correct for temperature. If the corrected reading is still o)er 1.!00 add a further small 9uantity of distilled 6ater and continue the process until a corrected S( reading of 7et6een 1.1*0 and 1.!00 is o7tained.55llo6 any sediment to settle in the mi+ing tan# then the electrolyte is ready for use.'illin) %,e Cell$ Before filling cells8 the special transit plugs should 7eremo)ed and disposed of. In the case of steel cells8 the plug is a ru77er 7ung located inside the )ent plugand8 in plastic cells is a plastic cap fitted in place of the )ent plug. Care must 7e ta#en that any sediment at the 7ottom of the mi+ing tan# is not distur7ed during the filling process. 'nough dry electrolyte has 7een supplied toensure all the cells are filled e)en if some electrolyte is left at the 7ottom of the mi+ing tan# 6ith any sediment. Cells may 7e filled either 7efore or after location on 7attery stands8 6hiche)er is more con)enient. 'lectrolyte may 7e pumped or siphoned from the mi+ing tan# either directly into the cells or if no6 coolinto a plastic >ug for filling the cells. Do not scoop up electrolyte directly from the tan# into another containers as this may distur7 any sediment in the tan#. CAUTION# Ne+er $%ar% %,e $ip,on !" $uckin) %,e end o( %,e $ip,on %u!e6 $e+ere in7urie$ can re$ul%& &he appro+imate )olume of electrolyte per Cell is sho6n in the ta7le 7elo6. .ill plastic cells up to the ma+imum le)el line sho6n on the outside of the container and steel cells up to the ma+imum le)el on the le)el tu7e. 0O NOT O5ER'ILL as this 6ill cause high specific gra)ities and conse9uential damage in later ser)ice 6hen electrolyte falls to the correct le)el through loss of 6ater. Clean and dry the e+terior of all cells using only 6ater 6ith a little detergent added. ?ightly coat the terminal 7olts and nuts8 remo)ing nuts and intercell connectors if cells are already made up into 7loc#s or crates8 6ith petroleum >elly to inhi7it corrosion. &he cells are no6 ready for assem7ly into place on 7attery stand or into the appropriate cu7icle. !LLN%M &'()8%L2M!%4"#$!*5 R'"!!L!"R%L#&L),L 11$110.27,L 1.$1.0.41,L 24$240.33,L 30$300.31,L 40$400.73,L 45$450.73,L 55$550.64,L 65$650.56,L .0$.01.63,L 100$1001.53,L 120$1201.4.,L 140$1401.33,L 150$1501..3,L 160$1603.42,L 1.5$1.53.05,L 200$2003.05,L 230$2302.75,L 270$2702.45,L 300$3002.15,L 340$3404.33,L 370$3704.13,L 400$4003./2,L 435$4353.71,L 470$4703.50,L 520$5206.17,L 560$5606.00,L 600$6006.67,L 650$65013.5,L 740$74013.0,L .40$.4012.5,L 1000$100010.0,L 1250$125010.4,L 1500$15007.5.,M 11$110.27,M 1.$1.0.37,M 24$240.33,M 30$300.31,M 40$400.73,M 4.$4.0.64,M 55$550.56,M 65$651.0.,M 75$751.02,M /0$/01.52,M 110$1101.31,M 125$1251.72,M 140$1401.50,M 160$1603.0.,M 1.5$1.52..4,M 205$2052.42,M 225$2252.33,M 250$2502.17,M 270$2704.33,M 300$3004.17,M 320$3204.00,M 340$3403.75,M 355$3553.5.,M 3.0$3.03.42,M 400$4003.17,M 450$4504.50,M 520$5206.25,M 600$60012.7,M 675$67512./,M 750$75011.7,M 1000$100012.0,M 1250$125015.0,0 10$100.42,0 20$200.2/,0 30$300.64,0 40$400.51,0 50$500.77,0 50$501.35,0 65$651.1.,0 .0$.01.00,0 /0$/02.1/,0 100$1002.12,0 125$1251..7,0 150$1502..3,0 1.5$1.54.75,0 200$2004.4.,0 235$2354.06SECTION 8General In$%alla%ion In(orma%ionBhen assem7ling cells into 7atteries8 ma#e all the short intercell connection first8 ma#e the inter4ro6 on inter4tier connections ne+t and lastly only ma#e connections to the charger or load ha)ing made surethat the 7attery is isolated else6here from 7oth charger and load.Bhen 6or#ing on a 7attery ha)ing a large num7er ofcells8 put cells into position and 7olt on inter4cell6connectors to ensure correct positions8 7ut then remo)e a connector e)ery 10th cell or so to pre)ent the high )oltage 7uilding up as more cells are connected.Bor#ing on a high )oltage connection could 7e dangerous if any part of the 7attery is earthed either accidentally or deli7erately. 0nce all cells are in position8 chec# insulation of each section to earth and the )oltage of each section @10 cells G 1! )olts nominalA and if good8 replace the missing connectorsand then inter4ro6 connectors and finally8 the main connections to charger and load.Bhen high )oltage 7atteries are installed in ca7inets8it is prefera7le if the ca7inets are loc#a7le.It is prefera7le if a ;permit to 6or#< system is employed for installation and maintenance of any high )oltage 7atteries.&a#e great care not to allo6 metal o7>ects to short circuit connectors or terminal pillars of opposite polarity of 7et6een connectors or pillars and cell case if the cell has a steel case.S%eel Ca$e Cell$ Depending on their design8 all steel cased cells ha)ean electrical conducti)e connection to the steel case caused 7y the electrolyte. &herefore a )oltage potential can 7e measured 7et6een cell cases and terminal or connectors. Cells should 7e mounted on the insulators pro)ided. &he steel cased cell8 e)en 6hen protected8 must 7e considered li)e and if cells are mounted in steel ca7inets8 ade9uate precautions must 7e ta#en to ensure insulation 7et6een ad>acent cell cases and 7et6een cell cases and ca7inets 7oth during assem7ly and throughout ser)ice life. Care should 7e ta#en to ensure a gap of 15mm 7et6een ad>acent steel cells8 although inter4cell connectors pro)ided 6ill normally ensure ade9uate spacing 7et6een cells in the same ro6. 5fter all cells are in position8 chec# the position of thehinge )ent plugs and if necessary8 remo)e and refit )ent plugs so that none of the hinges are positioned to the front of the 7attery. &his 6ill help to ma#e su7se9uent maintenance easier. &he complete plastic )ent plug is fitted into the cell 6ith a 7ayonet fi+ing and can 7e remo)ed and turned through 10 degrees 7efore refitting. Pla$%ic Cell$ 5t lo6 )oltages the plastic case itself is a sufficient insulator for most applications. In special cases or for high )oltage 7atteries8 insulators 6ill 7e supplied and cells should 7e mounted on these. Cells should 7e arranged so that the lines imprinted on the container indicating minimum and ma+imum le)els of electrolyte are clearly )isi7le. 5fter the cells are installed and all connections madesecure8 the 7attery is ready for its commissioning charge. SECTION 9Commi$$ionin) C,ar)e5 commissioning charge has to 7e carried out 7eforesetting a 3ic#el Cadmium 7attery into operation.Before applying any charging )oltage remo)e theTran$por%: S%ora)e Plu)$8 e+cept in the /2? 102 cells8 the Upper Black Ru!!er Seal from the centralscre6 should 7e remo)ed.Bhere conditions do not permit continuous 6or#ing8 the charge @and discharge 6here re9uiredA may 7e split into sections8 6ith a rest period 7et6een8 pro)iding that the total duration of charge=discharge is as specified.'ssentially8 the commissioning charge is designed toensure that all cells are in a fully charged state8 in good condition and in 7alance 6ith each other. &his is necessary e)en if the 7attery is e)entually to 7e operated in a partly charged condition. It is ad)isa7lefor the commissioning charge to 7e carried out 6ith the load isolated from 7attery=charger and is essential if the high )oltage may damage the load de)eloped during commissioning.&he room should 7e 6ell )entilated during the commissioning charge and particular care ta#en to e+clude any means 7y 6hich gas gi)en off during charge might 7e ignited.T"pe o( C,ar)er Chargers 6ith B @Constant CurrentA or IU Characteristics @Constant .loat ,oltage ChargersA Chargers must 7e capa7le of raising the cell )oltage to 1.-0 )olts per cell. Bhere 7attery and charger ha)e 7een supplied for operation on a system 6ith close )oltage limits8 then a special facility should ha)e 7een incorporated into the charger to allo6 the high commissioning )oltage to 7e de)eloped. 0ften this facility is 7rought into circuit 7y an internal t6o4position s6itch mar#edC ;5U&0< 4 ;C0%%ISSI03ust the loc# nut nearest the cell lid. &his is set to compress the sealing gland and electrolyte lea#age may occur later if it is distur7edElec%rol"%e C,an)e$ 2otassium hydro+ide electrolytes slo6ly a7sor7 car7on dio+ide from the air. &he gas forms compounds 6ithin the electrolyte8 6hich increase theinternal resistance of the cell and hence reduce performance. 3ormally8 a7sorption of car7on dio+ide ta#es many years to ha)e a serious effect on performance8 7ut is more rapid if 7atteries are operated at high temperatures or in en)ironments 6ith unusually high concentrations of car7on dio+ide8i.e. from engine e+haust8 etc. &he reduction in performance is not permanent and the cell can 7e returned to good condition 7y rene6ing the electrolyte. S'C Industrial Battery Co. ?imited recommends that electrolyte 7e changed if the potassium car7onate content reaches -5 grams per litre of electrolyte. &he only 6ay to determine the car7onate contents is 7y chemical analysis8 it is suggested that this is carried out e)ery ! or 3 years. 5ny good la7oratory can carry out the analysis or S'C Industrial Battery Co. ?imited 6ill 7e pleased to arrange for the test to 7e done for you. 5 !0ml sample of electrolyte should 7e made up in a small plastic 7ottle8 using small amounts of electrolyte from the cells in the 7attery. Do not ta#e the 6hole sample from one cell. &a#e the sample 6hen the 7attery has 7een fully topped up and after charging to mi+ any recent additions of distilled 6ater. Seal the sample 7ottle tightly8 pac# carefully and send to S'C Industrial Battery Co. ?imited 6here it 6ill 7e dispatched to the la7oratory. 2lease enclose details of the 7attery from 6hich the sample 6as ta#en. &he details re9uired are 7attery serial num7er8 type and num7er of cells and the date of commissioning. If the analysis sho6s that an electrolyte change is re9uired8 order from S'C Industrial Battery Co. ?imited the correct 9uantity of dry electrolyte plus a 10D e+cess to allo6 for spills and 6aste. 0nce the electrolyte has 7een recei)ed and arrangements ha)e 7een made for the 7attery to 7e out of ser)ice for a day or t6o8 proceed as follo6s. WEAR PROTECTI5E CLOT/ING6 GLO5ES AN0 GOGGLESDischarge the 7attery at a current e9ual to 10D of the 54hour capacity until the )oltage of eac, cell is less than 0.4,.&hen isolate the 7attery from 7oth charger and load and disconnect all inter4cell connectors. 2ro)ide sufficient containers @steel or plasticA to hold the entire electrolyte contained in the 7attery. $emo)e each cell from the stand or ca7inet and up end them to drain the entire electrolyte into thecontainers. ?ea)e each cell to drain for 5 minutes o)er the container8 then clean the outside of each cell 6ith clean 6ater and detergent and dry 7efore draining the ne+t.&he procedure from there on is the same as if the cells 6ere 7eing filled for the first time. See instructions for filling the cells.T/E OL0 ELECTROLYTE IS CAUSTIC AN0 T/ERE'ORE 0ANGEROUS& 0ISPOSE O' IT IN A RESPONSIBLE AN0 SA'E *ANNER&SECTION >Te$% Procedure$&he follo6ing procedures may 7e used to determine the potassium hydro+ide and potassium car7onate content of the electrolyte if desired. 'ither method may 7e used.>&-0e%ermina%ion o( KO/ and K2CO3 in %,eElec%rol"%eC1'%IC5?S&rade 3ameChemical DesignationChemical.ormulaausti9 :otas($otassium (yd+o;ide,%0)istilled ,%0*1By using &a7le ! 6e only need to #no6 the difference of p4@m4pA8 6hich 6ill allo6 us to findthe respecti)e )alue for the electrolyte density in g /01=18D/01 or g=cu.cm. In column C!. In the e+ample8 6e ha)e p4@m4pAG1*.3. 2arallel )alues in column C! of &a7le ! o7tained 7y interpolation are !1".5g /01=18 1.45D /01 and 1.1-3 g=cu.cm. Bithout ha)ing to interpolate 6e can find from &a7le ! that the concentration is 7et6een !1!.03 and !!5.*g /01=1 or 1.1! and 1*.14D or 1.1- and 1.1g=cu.cm (enerally this accuracy is sufficient8 therefore interpolation is not necessary.0e%ermina%ion o( KO/ and K2 CO3 in Elec%rol"%e .Al%erna%i+e *e%,od !Dui:mentE!+lenmaye+ ?las=@9a:.500ml-+aduated :i:ette@ 9a:.5 ml"it+atin> bu+ette@ 9a:. 50mlRea>entsE0yd+o9(lo+i9 a9id@ 07@ 1 N)istilled Fate+al9o(oli$(enol:(t(alein 1GMet(yl o+an>e +ea>ent5nalysis 2rocedure.ill the titrating 7urette 6ith 1 3 hydrochloric acid up to :ero point. Using a pipette introduce 5 ml of potassium hydro+ide into the 500 ml 'rlenmayer flas# and dilute it 6ith appro+imately 504100 ml of distilled 6ater.3o6 add 345 drops of phenolphthalein8 6hich 6ill cause the solution to change its colour to )iolet. Bhilst sha#ing this 'rlenmayer flas# carefully8 let the hydrochloric acid flo6 slo6ly from the 7urette until the solution 7ecomes colourless. $ead the 9uantity of hydrochloric acid used on the 7urette8 note it and mar# it 6ith ;Consumption 1< @C1A.3o6 add to the colourless solution 344 drops of methyl orange reagent8 6hich 6ill change the colour of the solution to yello6. Su7se9uently #eep sha#ing the 'rlenmayer flas# carefully and #eep adding hydrochloric acid slo6ly from the 7urette until it changes its colour to orange. Chec# the total 9uantity of hydrochloric acid used on the 7urette8 note it and mar# it 6ith ;Consumption !< @C!A.CalculationC,2 %39ontentsE2 ; &2-1) ; 4,2 %3 *5 A > ,2 %3 *1 ,%0*1 Model#ea+ o? manu?a9tu+e(a+>in> volta>eINDIID!A" CE"" READINGSell4loat"estell4loat"estell4loat"estell4loat"estell4loat"estNo.8olts8oltsNo.8olts8oltsNo.8olts8oltsNo.8olts8oltsNo.8olts8olts1265176101227527710232.537.10342/547/10453055.010563156.110673257.2107.335..310./345/.410/103560.5110113661.6111123762.7112133.63..113143/64./114154065/0115164166/1116174267/21171.436./311.1/446//411/204570/5120214671/6121224772/7122234.73/.123244/74//124255075100125Rema+=s and Re9ommendationsESEC1i>nedESECIndustrial Battery Co.Industrial Battery Co.12