PKS™ - TDC 3000® TAB PD 09

CUSTOMER PAGE B04 (A)

RESOURCE MANUAL DATE 7 OCT 1990

MAINTENANCE OF LEAD CALCIUM BATTERIES

Background There are three basic styles of lead calcium batteries in use. One style
has caps that can be removed, one style has the caps sealed to the top,
and one is sealed air tight. Each style has different maintenance
requirements.

1. REMOVEABLE CAPS - This style allows access to every cell. The

electrolyte level can be inspected in every cell and water added if
needed. A hydrometer can be used to check the specific gravity in
each cell. This will indicate the level of charge and also allow
detecting a failed cell. This style will tend to lose water at a higher rate
than the other styles and will also produce the most gassing.*
2. SEALED CAPS - The caps cannot be removed on this style. This style
will have a hydrometer built into one of the cells. This hydrometer has
three indications, GREEN indicting a charge of 65% or above, DARK
indicating a charge less than 65%, or CLEAR (or YELLOW) indicating
the electrolyte is low and the battery needs to be replaced. It may
not be possible to determine the electrolyte level in the five cells not
containing the hydrometer. This style does have vents and will lose
water and produce some grassing.
3. SEALED NON-VENTED - This style is the most expensive of the three.
It has no vents, will not lose water, or normally will not release any gas.

Caution WARNING - Lead Calcium batteries contain a dilute sulfuric acid.

Contact with this acid will cause burns and will destroy clothing. Safety
glasses should be worn. A solution of baking soda and water can be
used to neutralize the acid. A battery may produce an explosive mixture
of gasses. A spark or flame near a battery could ignite these gases
causing an explosion. If the liquid level drops below the plates, there is a
danger of a spark occurring between the plates causing the battery to
explode. NEVER charge a battery that has a low liquid level.

* Gassing = The evolution of gases (caused by electrolysis) from one or

more electrodes during charging.

Continued on next page

Honeywell Automation and Control Solutions

 TAB PD 09 B04 (A) PAGE 2 DATE 7 OCT 1990

MAINTENANCE OF LEAD CALCIUM BATTERIES, continued

Action It is good practice to inspect batteries every month. Lead Calcium batteries
need to be load tested periodically to determine if they have lost any of their
capacity. Load testing will also show if any of the cells are bad. There are
several types of load testers available through automotive supply houses.
The load test should be applied to each battery based on the manufacturer's
specifications to see that it has the capacity to meet the needs of the
application.

If you have batteries that water can be added to, use caution that they are
not overfilled. This will reduce performance and life. Excess water loss is a
sign of overcharging. High battery temperatures or large ambient
temperature swings will increase water loss.

Visually inspect the battery for cracks, bulges, or signs of electrolyte leakage.
The batteries should be kept clean. Wash the battery with a diluted
ammonia or soda solution first to neutralize any acid that might be present.
Rinse the battery with clean water.

Inspect the cables to see that they are clean and the connections are tight.
A thin coating of petroleum jelly could be used on the battery post and cable
clamps to reduce corrosion.

The Honeywell Battery Backup Unit (BBU) should be tested for correct
charging rates and operation. Follow the instructions in the BBU Service
Data manual SO-02-00.

Note The BBU is intended to supply backup power for 30 minutes at a rate of 40
amps or less. This would require batteries with an ampere-hour capacity of
20 or more. Ampere-hour (AH) is a rating of the energy capacity of the
battery. A 65 Ampere hour battery could support a current draw of 65
amperes for one hour or 32.5 amperes for 2 hours. This would also be an
indication of the charging time required for the battery. The TIME (in hours)
times the RATE (in amperes) would have to equal 65 to fully recharge a
discharged 65 AH battery. These values are not absolute. Battery size,
condition, temperature, and rates can affect discharge and recharge times.

Honeywell Automation and Control Solutions