Chapter - 3

T10A Alkaline Cells/Batteries

3.1 The electrolyte in Alkaline Cells is basically an Alkali namely Potassium Hydroxide which acts as a passage for ions, but has nothing to do with the chemical reactions throughout the charging and discharging. As a consequence, the electrolyte specific gravity remains constant and it cannot be an indication for the state of the charge. The electrolyte resistance remains almost same during discharging. Thus the cell is assured to render a service with the voltage characteristics maintained almost unchanged during its discharging. The discharged condition of the cell can only be known by Voltage. The end point voltage of an Alkaline Cell is normally 1.0V/Cell. There are mainly two types of Alkaline Cells:1. Jugner - Nickle Cadmium (Ni-Cd) Cells 2. Edison - Nickle Iron (Ni-Fe) Cells (These cells are not as popular as Ni-Cd Cells). 3.2 Nickle-Cadmium Cells: Positive Material Negative " Electrolyte Chemical reactions: 2Ni(OH)2 + Cd (OH)2 2 NiO OH + Cd + 2H20 - Nickle Hydroxide - Ni(OH)2 - Cadmium " - Cd(OH)2 - Potassium Hydroxide - KOH - Sp.Gr. 1.17 on charge.

It can be observed from the above equation that electrolyte is not figuring in chemical reactions. Separator Material - Non-woven synthetic fibre or plastic material or cloth Container - Steel or stainless steel as the electrolyte used is non-corrosive. 3.3 Types of Ni Cd Cells: There are basically two types of NiCd Batteries/Cells distinguished by the construction of the electrodes. 1) Sintered Plate type 2) Pocket Plate type There are two types of Sintered Plate Type of batteries distinguished by shape. 1) Rectangular Vented Type 2) Sealed Cylindrical Type 3.4 Sintered Plate Nickel Cadmium Cells (Rectangular Vented): In case of Sintered plate battery the basic electrode plates are made by sandwiching Pure Nickel Mesh/Nickel plated steel mesh/perforated sheet between two layers of

Fig.3.1 Cross sectional view of the sintered plate type Nickle cadmium Rechargeable Battery (Vented Rectangular)

Fig.3.2 Cross sectional view of the Pocket plate Type Nickle Cadmium Rechargeable Battery (Vented Rectangular) Nickel powder and sintering to 1000 deg. C in a sintering furnace under reducing atmosphere. Plates thus formed would have porosity of almost 80%. Into these pores the active materials are impregnated using different techniques. Plates impregnated with Nickel Hydroxide would become positive plates and those impregnated with Cadmium Hydroxide would become negative plates. These electrodes are generally of thickness varying from 0.6 mm - 1.5 mm. Pure Nickel or Nickel plated tabs are spot welded to the plates to act as electron carriers. The positive and negative plates are stacked together with a separator in between to make positive and negative bunches. The tabs of positive and negative plates are spot welded or bonded to the terminals which finally protrude out of the cell as positive and negative terminals. The separator used in the battery is non-woven synthetic material with special
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proportions. The size of the plate and the number determine the Ah capacity of the cell. To make cell of higher Ah rating the plates have to be bigger which would need bigger sintering furnace. 3.5 Pocket Plate Nickel Cadmium Cells (Rectangular Vented): In the case of Pocket Plate NiCd Cells, the basic active materials, namely chemicals of Nickel and Cadmium are made externally. These powders are then packed into pockets of Nickel plated steel perforated strips. These strips are cut to the required size depending on the width of the plate and the horizontal strips are held together by means of side clips to form the plates of required length. These plates are welded or bonded together as in the case of sintered plate cell to the electrodes. The separator used in this case could be a cloth or plastic material. Pocket plate electrodes generally have a thickness of more than 2 mm. On account of the limitation imposed by the size of the sintering furnace and long process time involved in chemical process in making sintered plate electrodes, Cells of Ah upto 40 are made in sintered plate type and cells of Ah above 40 are made in pocket plate. 3.6 Constructional Features: On account of the non-corrosive nature of the alkali, the Nickel Cadmium Cells are made in Nickel plated steel containers or Stainless Steel containers. However, cells are also made in plastic containers like poly propylene, high impact poly styrenes or nylon. In these cells also there is a gas evolution which arises as a consequence of electrolysis of water in the electrolyte. In order to vent out the gases evolved to avoid bulging of the cells due to internal gas pressure, the cells are equipped with "Vent Plugs". Vent Plug is a device similar in construction with the cycle valve plug to release gases built-up within the cell to outside by expandable rubber sleeve, at the same time preventing Carbon-dioxide from entering the cell. The vent plug is also, a device which could be opened to top-up the electrolyte which gets evaporated. On account of the venting device, these cells are called "Rectangular Vented Cells". This venting device is there in both sintered plate as well as pocket plate cells. 3.7 Sealed cylindrical cells: The sealed cylindrical cells are also sintered plate type cells. Electrodes used in these cells are also made in the same way as the electrodes in the rectangular cells except that the electrode is made much thinner to enable a set of positive and negative plates separated by a separator cloth to be wound tightly to go into the nickel plated sealed cylindrical container. The positive electrode is welded to the top lid and negative to the body of the cell with an insulation between them. Finally the cell is crimped at the top to avoid leakage of the electrolyte. Similar to the venting device in rectangular cells, there is also a device under the positive button which is not externally visible. This device is permanently fixed and therefore, can not be opened and replaced to add back evaporated electrolyte. Therefore, the sealed cylindrical cells get permanently damaged once the electrolyte gets dry. The sealed cells are generally made to international sizes as they are to be housed in a pre-determined space available in an instrument or gadget. Cells required to give the desired voltage are welded at top and bottom by Nickel plated steel strips in series as per the user's configuration or depending on the space available.

Fig. 3.3 Cross Sectional View of the sintered plate type sealed cylindrial rechargeable Nickle cadmium cell 3.8 Applications: In all the applications where the cells/batteries could be located outside, the rectangular vented cells could be used with the only constraint that the cells should be mounted only in vertical orientation as otherwise the electrolyte might spill out. On account of the low internal resistance and also due to the low thickness of the plates of the sintered plate cells compared to pocket plate cells, in all applications which call for high rate of discharge, sintered plate type of batteries are used. Otherwise for general applications any one type could be used. However, in all cases where the cells are to be mounted horizontally or inside any instrument or gadget into a pre-determined space, the sealed cylindrical cells are used. 4 Ah and 1 Ah NiCd Cells are now being used in place of 6 I Cells in S & T Installations. 3.9 Advantages & Disadvantages: On account of the fact that there is a large pool of electrolyte available and also the plates are not kept very tight, the rectangular cells could withstand much more abuse like accidental shorting, high rate charging or high rate discharging. Further, since the electrolyte could be replaced on evaporation, these cells last longer than Sealed Cells provided they are maintained properly. On account of the fact that the active materials are impregnated into the pores of the plates there is no shedding of the active materials in the case of Sintered plate battery compared to the pocket plate battery. The only disadvantage is that these cells cannot be placed in horizontal orientation. On the other hand, Sealed Cells are very convenient to use as they do not need maintenance and they could be mounted in any orientation. But on account of a few drops of electrolyte contained in the cell, any evaporation of these few drops due to environmental temperature or short circuiting or over charging makes the cell go dead. For the same reason Sealed Cells are not supposed to be charged at rates higher than C/10, whereas the rectangular cells could be charged at any rate. The most impending factor in the case of Sealed Cells is the high cost, more than double that of the Rectangular Cells. It is, therefore, advisable to go for the Rectangular Cells wherever the application does not restrict the orientation and the cells are kept outside the equipment, can be kept vertical, and there is a possibility that exists to arrange for periodical maintenance (once in 3 months). 3.10 Comparison of Rectangular Vinted and Sealed Cylindrical batteries: ADVANTAGES
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S. No. 1

2.

Rectangular Vented Nickle Cadmium rechargeable batteries Electrolyte volume is large and there is a flood of electrolyte over the top of the plates. As such drying of the cell on account of electrolyte evaporation does no occur. Electrolyte evaporated could also be replenished. Since the plates are loosely plated in cell, the chances of failure of the cell on account of burrs/protrusions on the plates or on account of dentrite growth are very little.

3.

4.

5. 6. 1.

Sealed Cylindrical Nickle Cadmium Rechargeable batteries Due to the sealed nature and compactness of design, the electrolyte is limited to that absorbed by separator. Evaporation of electrolyte on account of environmental temperature or over changing will lead to a the death of the cell. Due to the fact that the plates are rolled tightly to go into the cell container to give high energy density, chances of failure on account of piercing of separator due to burrs/protrusions or on account of dentrite growth are high. Can take a rate of charging due to low Charging rate higher than C/10 not risk of total evaporation of electrolyte recommended as this would lead to on account of flooded electrolyte electrolyte evaporation and drying of sealed situation. cylindrical cells. If by chance the cell gets reversed due Chances of restoration to normalcy if cell to wrong connection or over draining reversals taken place are minimum. of battery, the normalcy could be restored by pulse charging Due to flooded nature of electrolyte Due to limited electrolyte, the life is short the life is long. relative to rectangular cells. Cost of rectangular cell is lower Cost is high.

Disadvantages
Cannot go into any compartment or When the technology of the manufacture of any gadget due to possibility of sealed cylindrical cell is perfect and electrolyte leakage. hermetically sealed, electrolyte does not leak, can go into any compartment or gadget. The cells have to be kept only in Cells could be left in any orientation as the vertical orientation due to flooded electrolyte is limited and cells are sealed. nature of electrolyte

2.

Table1: Comparison of Rectangular Vented and Sealed Cylindrical batteries. Advantages & disadvantages of rectangular vented nickle cadmium rechargeable batteries/cells over sealed cylindrical nickel cadmium rechargeable batteries/cells. 3.11 Comparison of nickel cadmium system with lead acid system: In order to highlight the advantages of Nickel Cadmium System over the lead acid system, a comparison of both the systems is made below. The statements made, and conclusions drawn are based upon the data presented in the book 'Alkaline Storage Batteries' by Falk & Salkind. As stated by the authors themselves, these data should be used for a rough comparison since considerable deviations exist between different designs within a given system. 3.12 General Characteristics: General Characteristics of the two systems are reproduced in Table II. It could be concluded from the table that Nickel Cadmium in general has (i) The same energy density, (ii) 2.5 times better high rate discharge capacity, (iii) 2.5 times better performance at low temperatures, (iv) 1.25 times less internal resistance, (v) 0.7 times better charging properties (vi) 0.6 times the Wh efficiency, (vii) 3 times better charge retention (viii) 1.3 times more life & (ix) 5 times better mechanical properties.
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----------------------------------------------------------------------------------------------------------------S. No. Particulars NiCd Sintered Lead-acid Vented cells Cells ----------------------------------------------------------------------------------------------------------------1 Energy Density 3 3 2. High rate discharge properties 5 2 3. Low temperature properties 5 2 4. Internal resistance 4 5 5. Charge properties 5 3 6. Ah & Wh efficiency 3 5 7. Charge retention 3 1 8. Life 4 3 9. Mechanical properties 5 1 ------------------------------------------------------------------------------------------------------------Table 2: Comparison of nickel cadmium system with lead acid system 3.13 Discharge Characteristics: The discharge characteristics of the two systems are presented in Fig. As could be seen from the graph, there is a striking difference between the alkaline systems on one hand and lead acid batteries on the other. While the capacity of the alkaline cells decreased relatively little at increasing discharge rate, a rapid fall in capacity of the lead acid cells occurs as soon as the current exceeds the C5 or C10 rate. This fundamental disadvantage of the lead acid system is connected with the limited time available for diffusion of the sulphuric acid and also with the increasing sulphation on the surface of the plates at higher rates. Among the alkaline cells, the best high rate performance is obtained with sintered plate nickel cadmium.

Fig. 3.4(a) Discharge characteristics of Lead Acid & Nickle Cadmium Cells

Fig. 3.4(b) Expected Life at various temperatures

3.14 Internal Resistance: The high internal resistance makes the lead acid system inferior to nickel cadmium system in heavy discharge conditions. 3.15 Charge Characteristics:
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Generally speaking, the most favourable charge properties are found with the vented nickel cadmium cells. These cells can be charged according to a large number of methods and in a short time. The temperature range for charging is very wide and the cells can be heavily overcharged without damage. Lead acid cells have reasonably good charge properties. The constant charge current, however, is limited to a relatively low value and further excessive overcharging has a detrimental effect. 3.16 Ah and Wh Efficiency: Capacity is more for Ni-Cd Cells. 3.17 Charge Retention: The Charge Retention properties of Ni-Cd battery indicate 70% of charge retention even after 6 months of charge, whereas lead acid battery looses its capacities. This gives the advantage that after any given unused time, the battery can be immediately used. 3.18 Life: No design of lead acid batteries reaches the life of alkaline system. But the actual life cycles depend upon the design and use of the system. 3.19 Mechanical Properties: Alkaline Batteries in general have good mechanical properties. Many of them are used in military and space applications in which they have to meet severe requirements for resistance to mechanical shocks, accelerations and vibrations. In this category fall the vented sintered plate nickel cadmium batteries. Generally speaking the designs in steel containers are more resistant to mechanical abuse than those in plastic containers. The resistance of Lead Acid Batteries to mechanical maltreatment is not as good as that of alkaline batteries. The material in the cell containers is normally hard rubber and the grid material in the electrodes is a lead alloy. Hard rubber has a poorer resistance than the material in the alkaline cell containers, and the lead alloys are, of course, not as strong as steel. 3.20 Conclusion: The fundamental and the important advantage in nickel cadmium system over that of lead acid is 'The electrolyte does not participate in the electro-chemical reaction, it only acts as a medium for the movement of ions. Therefore, the electrolyte will not corrode the plates. So, theoretically this point will ensure indefinite life for the system. But other practical aspects limit the life to a maximum of 2000 deep discharge cycles in ideal situation. In lead acid system the electrolyte participates in the electro-chemical reaction, corroding the plates very fast, limiting the life to a smaller number of cycles. Since the electrode mechanical properties are poor, the system fails very soon compared to nickel cadmium normal running conditions. Nickel Cadmium Cells may be overcharged, over discharged, accidentally short circuited, charged in reverse direction, or left standing idle in a discharged condition indefinitely without injury. The diseases such as, Sulphation, Buckling, Sedimentation or terminal corrosion do not occur in case of Ni-Cd Cells. The capacity of Ni-Cd Cell is 50% greater than that of LA Cells. 3.21 Use of sealed cylindrical nickel cadmium rechargeable cells in place of 1.5V Dry Cells in S&T Installations:

In places where large D.C. currents are not essential and the maintenance needed is minimum, S&T Dept. is making use of 6-I type dry cells with 1.5 V/Cell. The main disadvantage of this type of cell is, they are to be discarded once discharged. And they do not have any return value also. Another disadvantage with this type of cells is certain amount of discharge takes place during their shelf life. This is having a serious effect on the delay taking place for real use from the date of manufacture. To avoid such disadvantages the 6-I type dry cells are replaced with 4 Ah Ni-Cd sealed cylindrical cells which can be recharged 500 times before they reach their life end or 1 Ah Ni -Cd cells which can be recharged 100 times. The initial cost of the sealed cylindrical Ni-Cd Cell is very high when compared with a 6-I type dry cell, an additional charger is also needed for recharging of cell which is at an extra cost, the number of Ni-Cd Cells needed are more for the same output when compared to 6-I cells (voltage of Ni-Cd is 1.2V and 6-I is 1.5 V). Yet, the cost of the Ni-Cd Cell works out to be economical in long run, as a result of repeated recharging number of cycles. In addition to this, the discarded Ni-Cd Cell has also return value. No maintenance is needed by Ni-Cd Cell and could be kept into any instrument/gadget in any orientation. Hence, at locations where maintenance is not possible and applications where the cells are to be kept in orientation other than vertical inside a compartment in a predetermined space, use of sealed cylindrical cells is recommended. 3.22 Advantages of Ni-Cd Sealed Cell over 6-I dry cell: 1. Rechargeable upto 500/100 times. This means this cost becomes 1/100th of the cost for single use manufacturing date and shelf life have no relation are to rechargeable nature of cell. Self discharge is not relevant since the cell is rechargeable Non-rechargeable and have to be discarded after cells are discharged.

2.

Whether used or not will have its own discharge

3. 4. 5 6.

Will fetch price as scrap, due to Nickle No recovery price. content. Can be operated at wide range of Self discharge is high at higher temperature temperature . Low weight Comparatively high weight. Cells of advance technology. Oldest type of technology. Table 3: Comparison of Ni-Cd and 6 I Cells.

3.23 Rechargeable Sealed Cylindrical Nickel Cadmium Cells: 1) The cell has a leak proof casing with no trouble of replenishing electrolyte, i.e., maintenance free. 2) The internal resistance of the Cell being very low, it is fit for high rate of discharging. 3) The cell is hermetically sealed and can be freely mounted in any direction. 4) The cell is mechanically rigid as the container is made of steel. 5) The cell offers a stable performance as a DC Power Source, as voltage fluctuations during most part of its discharge is nominal. 6) The cell withstands repeated cycles of charging and discharging as many times as 500 to 2000. Hence, it is highly economical. 7) The cell comes in a Compact, Light Weight design. 8) The cell operates over a wide range of temperatures i.e., -20o C to + 55oC. 9) Quick charging facility available. 3.24 Construction: The Sealed Cylindrical Nickel Cadmium Cell appears similar to Cylindrical Dry Cell but the material used and the internal mechanism are entirely different. Each Nickel Cadmium Cell has one Positive and one Negative Plate. These plates are basically made by applying a thick coating of Nickel Powder over a grid and then sintered to obtain a smooth porous sintered nickel plate. These sintered nickel plates are then subjected to chemical operations, and are made into Positive and Negative Plates separately. These positive and negative plates are wound together with a non-woven Synthetic Fibre Separator held between the two. This spiral plate assembly is kept inside a nickel plated steel/stainless steel container. This is sealed after the addition of electrolyte and assembly cover. The container acts as Negative Terminal and the cover as Positive Terminal. The cover is provided with a safety vent for the escape of gases in case the pressure inside the container exceeds the set safety limit. The electrolyte used in the cell is diluted Potassium Hydroxide Solution. 3.25 Critical Characteristics - Charge: Nickel Cadmium Sealed, Cylindrical Cells should be charged with constant current (DC). Charging with constant potential is not recommended.

Standard charging for these cells is carried out at 0.1 C ma for15 hours. (where 'C' is the Capacity of the cell in mAh). Quick charging cells capable of being charged within 7 hours also can be supplied against specific request. 3.26 Discharge: The Normal Voltage of Nickel Cadmium Cell is 1.2 V. The main differences existing among these cells are the discharge voltage variable with internal resistance and the discharge holding time. Indicates the typical discharge curves for sealed cylindrical Nickel Cadmium Cells and Dry Cells.

Fig. 3.5 Discharge Characteristics Of Dry Cells.

Fig. 3.6 Circuit Diagram of Ni-Cd And Constant Current Charging

The internal resistance makes possible the Sealed Nickel Cadmium Cells to hold the discharge voltage almost unchanged during the cycle of high-rate discharging. The cell voltage slightly goes down immediately after the start of discharging, gets stabilized and declines sharply at the final stage. 3.27 Self Discharge: Generally, any cell will undergo self discharge if kept out of use for some time after being fully charged, loosing its charged capacity. Self discharge is caused normally due to the following factors:Self decomposition of active materials on the positive and negative plates. Chemical reactions caused by impurities contained in active materials. 3.28 Expected Service Life : The termination of service life for sealed nickel cadmium cells refers to the state at which the discharge capacity of the cell declines to 60% of the rated capacity in due course of service and which cannot be recovered. The general causes which are considered to affect the fall of cell capacity, are the reduction in plate chemical reactional performance (aging), aging of separator and decrease in volume of electrolyte. The service life varies depending on ambient temperature, charge-discharge pattern and frequency of use. Longer service life can be achieved by careful handling of the cell such as, avoiding overcharging with currents higher than normal and avoiding repeated charging and discharging at an extra low or high temperature.

3.29 Charging Methods: Generally these cells are to be charged with constant current (DC). A typical circuit diagram of constant current charging is indicated. Trickle charging is recommended when a fully charged cell is kept idle for long periods in order to keep the cell in full state of charge. This is necessary to make up the losses due to self discharge during storage. This is done by a continuous charge at a very low current. 3.30 Dos & Donts: It is recommended that the battery room be provided separately from the circuits of the equipment. Contact terminals of the battery holder must be made of nickel plated steel or nickel clad copper. The battery room should be located away from heat generating part of equipment. Do not disassemble the cells. The electrolyte will hurt the skin and damage cloths. Handle the cells carefully to avoid short circuiting which may cause burns or fire. Do not throw the cell into a fire. It may sometimes explode. Do not connect different types of cells together and also avoid connecting old and new cells together. 3.31 Special Information: Batteries of multiple voltages are available. Single cells and batteries in rectangular type upto 65 Ah are also available. 3.32 Precautions while Handling: Charging: Be careful not to effect reverse charging by accident. Positive output terminal from the DC power supply should be connected to positive terminal of the cell/battery and negative output to the negative terminal. Avoid parallel connection of cells. Avoid using constant voltage charging of the cells. Do not charge the cell using charge current more than specified. Be sure to conduct charging within a temperature range of 0o to 45o C. Discharging:

Be sure to conduct discharging within -20o C to +55o C. Normal cut off voltage per cell is 1.0V. Avoid discharging below this limit. Repetition of over discharging will result in service life reduction and cause the leakage of electrolyte. Do not discharge the cell with currents more than 3 CmA continuously and more than 5 c ma instantaneously.

Storage: The cells have to be kept in non-corrosive, gas free, dry place preferably within ambient temperature of -20oC to + 55oC It is recommended to discharge the cell before storing for long periods. RDSO has specified sealed cylindrical Ni-Cd Cells under fixed Some salient points are as under. 3.33 General Requirements: The battery shall consist of sealed cylindrical rechargeable nickel cadmium cells connected in series for use in Rly. Telecom Circuits. These cells do not release gas under the normal charging and temperature conditions specified by the Manufacturer. The cells do not require addition to the electrolyte in use and are designed to operate during their life in their original sealed condition. Rated Capacity: The rated capacity (C/5) in ampere hours is the capacity at the five hour rate of discharge to a final voltage of 1.0V per cell at an ambient temperature of 27 deg. C + 3 deg.C. The A.H. rating of all the single cells to form a battery shall be same and this will determine the AH capacity of the battery. The individual cell shall have a safety vent to release dangerously high internal pressure. The manufacturer shall provide guarantee that sufficient safety device has been incorporated for venting out the built up pressure of gas in case of reversal of the cell or due to any malfunctioning to avoid danger to the operating personnel. The battery shall be properly housed in a fibre glass box with terminals brought out. terminals for external wiring shall be provided with insulating nut. The serial No.IRS:TC 53-1991.

The batteries shall normally be supplied as a single unit without float charger. If the purchaser specifically requires battery with built-in float charger, it shall be ensured that the battery is housed in the same casing and it shall be detachable to facilitate replacement of the same when required. The battery shall be capable of being stored at any temperature between +70 deg to 10 deg C without any damage and also capable of operating between the temperature range of +55 deg C to 10 deg. C.

The battery is intended for use for the communication installation by the side of the railway track, and also in the super fast train and, therefore, it shall be capable of withstanding rough use and vibration. The battery shall be capable of quick-charging also apart from trickle charge and shall be able of being charged from any state of discharge. The materials and workmanship of the battery shall be of good commercial quality and shall be free from defects which would interfere with the service for which it is intended.

3.34 Electrical Characteristics and Tests: 25 Nominal Voltage: The nominal voltage (closed circuit voltage) of a sealed cylindrical rechargeable Nickel Cadmium Battery shall be 1.2 times the number of cells connected in series. 25 Charging Procedure: The charging for this test shall be carried out at an ambient temperature of 27 deg.C + 3 deg.C at constant current and shall be 14 hours to 16 hours. 25 Discharging Procedure: After charging as in (b) above, the cell shall be stored for not less than 2 hours and not more than 4 hours at an ambient temperature of 27 deg. C + 3 deg. C. It shall then be discharged at 0.2 C Ampere rate at an ambient temperature of 27 deg. C + 3 deg. C. The duration of this discharge shall not be less than 4 hours and 45 minutes. The number of charge/discharge cycles shall be limited to 5 and if in any two consecutive cycles, the duration exceeds 4 hours and 45 minutes, the remaining cycles need not be conducted. If the above conditions are not met in all the samples, the lot shall stand rejected. d) Insulation Resistance Test: The insulation resistance between the negative terminal and the outer case shall not be less than 10 megaohms when measured with 250V D.C. e) Charge Retention Test: The battery shall be charged as in (a) above. The battery shall then be stored for 28 days on open circuit at an ambient temperature of 20 deg. C + 5 deg. C. After storage, batteries shall be discharged at a constant current of 0.2 C ma to an end voltage of 1.0V per cell. The duration of discharge immediately after 28 days storage shall not be less than 3 hrs. 15 mts. The fully charged battery shall be further charged at a current rate of 0.2 C ma for 24 hours at an ambient temperature of 27 deg. C + 3 deg.C. The battery then shall be discharged at a constant

current rate of 0.2 C ma until the no load voltage reaches to 1.0V times the number of cells connected in series. After the above discharge, the battery shall meet the requirements of rated capacity and it shall show no evidence of leakage or cell deformation. f) Low Temperature Performance Test: Immediately after charging, the battery shall be stored for between 16 to 24 hours at a temperature of 10 deg to 3 deg C and then discharged at that temperature at a current of 0.2 C ma until the no load voltage reaches 1.0V times the number of cells connected in series. The duration of discharge shall not be less than 3.5 hrs. g) High Temperature Performance Test: The discharged battery shall be stored in an ambient temperature of 55 deg. C + 2 deg. C for a duration in between 16 to 24 hrs. The battery shall be subjected to charge/discharge cycles at that temperature. The battery shall be charged by a current of 0.2 C ma for 7 hours followed within one hour by the discharge of 0.2 C ma until the no load voltage reaches to 1.0V times the number of cells, connected in series. The duration of the fourth discharge shall not be less than 2.25 hrs. h) Low Battery Indication: An illuminated indication preferably LED may be given on the cabinet in both the cases when the battery is supplied with inbuilt charger or the battery is supplied without charger. When the battery is fully charged, indication will not lit. When the battery is discharged to the end voltage of 1 volt per cell, the red indication should lit indicating that the battery has been discharged fully and required to be charged immediately. 3.35 Life Cycle Test: 25 Before life cycle test, the cell shall be discharged in accordance with above. 2) The following life cycle shall then be carried out irrespective of cell designation at an ambient temperature of 27 deg. C + 3 deg. C. Charge and discharge shall be at constant current throughout. Cycling shall be continuous except that it is permissible to allow the cell to stand for a short period at the end of discharge at each 25 th cycle in order to start each 26 th cycle at exact weekly intervals. Cycle No. Charge Discharge 1 0.2C5 A for 7 th hr 0.225C5 A for 2hrs 40 min. 2 to 23 0.225C5 A for 3 h 20 min. 0.225C5 A for 2hrs 40 min. 24 0.225C5 A for 3 h 20 min. 0.225C5 A to 1.0 V end voltage 25 0.2C5 A for 7 th hr. 0.2C5 A to 1.0 V end voltage

Table 4: Life Cycle Tests

Cycle 1 to 25 shall be repeated until the discharge duration on any 25th cycle becomes less than 3 hours. Leakage of liquid shall not occur during the life cycle test. 3.36 Shelf Life: Batteries stored for 2 years at an ambient temperature of 27 deg. C + 3 deg. C in a discharged condition shall be capable of meeting the full requirement of the specification.

3.37 Psophometric Voltage: The Psophometric Voltage level across the output terminals of the battery with inbuilt battery charger switched on shall not exceed 2 mv.rms, when delivering rated output current in the float mode. 3.38 Tests: Visual Inspection: The batteries shall be visually examined to ensure that the workmanship and finish is satisfactory and confirm for the general requirements. 3.39 Type Tests: The following shall constitute the type tests:(a) Visual Inspection (b) Electrical Characteristic Tests. (c) Life Test (d) Shelf Life (e) Psophometric Voltage only in case where battery is supplied with inbuilt battery charger. (f) Climatic and environmental tests. Number of samples for type test shall be selected from normal production at random. 3.40 Acceptance Tests: The following shall constitute the Acceptance Tests:(a) Visual Inspection (b) Electrical Characteristic test (c) Psophometric Voltage only in the case where battery is supplied with inbuilt battery charger. 3.41 Routine Tests: The following shall constitute the routine tests:(a) Visual Inspection (b) Electrical Characteristics (c) Psophometric Voltage only in the case where battery is supplied with inbuilt battery charger. Any of the material not complying with the standards may be rejected.

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