TECHFILL INSTALLATION AND INSTRUCTION MANUAL

For NICKEL-CADMIUM
ALKALINE STORAGE BATTERY

Index

Nos Date Edition Permission

1 14.7.2007 First edition All TF-Engineering

2
3

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 CONTENTS

Page
Type List and Precautions 3

Chapter 1 Basic Knowledge on Alkaline Battery 7

1-1 Introduction 7
1-2 Construction 7
1-3 Chemical Reaction during Charge and Discharge 8
1-4 Characteristics 9

Chapter 2 Installation of Battery

2-1 Condition for Battery Room 10
2-2 Unpacking and Inspection 10
2-3 Filling Cells with Electrolyte 10
2-4 Installation of Battery 11

Chapter 3 Initial Charging and Storage

3-1 Pre-charge Preparation 13
3-2 Charging Procedures 13
3-3 After-care of First Charging 17
3-4 Storage of Charged Battery 17

Chapter 4 Maintenance
4-1 Charging 18
(A) Floating Chargers 18
4-2 Influence of Temperature 18
4-3 Topping Up of Electrolyte 18
(A) For Plastic Cell Container 19
(B) For Stainless Steel Cell Container 19
4-4 Preparation of Electrolyte 20
4-5 Caution on Handling of Electrolyte 20
4-6 Renewal of Electrolyte 20
4-7 Cleaning 21
4-8 Storage of Battery 21
4-9 Regular Maintenance and Inspection 22
(A) Floating Charge Voltage 22
(B) Equalizing Charge 22
(C) Check Points at Inspection 23
4-10 Disposal 25

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 TECHFILL SERIES OF NICKEL CADMIUM ALKALINE BATTERIES

TSX (ULTRA HIGH RATE TYPE)

Max. Dimensions (mm) Max. Weight Max. Weight
C5
Type Length Width Height (Unfilled) (filled)
(Ah)
(L) (W) (H) (kg) (kg)
TSX 10 10 29 81 218 1.05 1.24
TSX 20 20 36.5 81.5 244 1.25 1.43
TSX 30 30 42.5 81.5 255 1.65 1.92
TSX 40 40 42.5 81.5 245 1.75 2.00
TSX 50 50 49 81.5 244 2.00 2.24
TSX 60 60 62 138.5 267 4.50 5.60
TSX 80 80 62 138.5 267 5.10 6.18
TSX 90 90 74.5 80.5 243 3.40 3.88
TSX 100 100 70 134 285 5.50 6.52
TSX 120 120 79 139 365 7.50 8.80
TSX 140 140 79 139 365 7.60 8.82
TSX 170 170 79 139 365 7.90 9.17
TSX 190 190 79 139 365 8.50 9.70
TSX 200 200 107 166.5 348 11.00 13.04
TSX 220 220 107 166.5 348 13.00 14.92
TSX 230 230 107 166.5 348 13.05 14.98
TSX 240 240 107 166.5 348 13.10 15.02
TSX 250 250 107 166.5 348 13.20 15.12

TPH (HIGH RATE TYPE)

Max. Dimensions (mm) Max. Weight Max. Weight
C5
Type Length Width Height (Unfilled) (filled)
(Ah)
(L) (W) (H) (kg) (kg)
TPH 10 10 48 81 245 1.5 1.8
TPH 20 20 68 134 245 2.4 3.0
TPH 31 31 70 134 285 3.0 4.0
TPH 41 41 80 141 370 4.0 6.0
TPH 51 51 80 141 370 4.6 6.2
TPH 61 61 80 141 370 5.0 6.5
TPH 71 71 106 164 345 6.5 9.0
TPH 81 81 106 164 345 7.5 9.5
TPH 91 91 164 167 345 8.6 12.9
TPH 101 101 164 167 345 9.0 13.0
TPH 121 121 164 167 345 10.5 14.0
TPH 151 151 138 276 420 14.5 19.5
TPH 181 181 138 276 420 15.0 20.0
TPH 201 201 176 291 510 22.0 35.0
TPH 226 226 176 291 510 23.0 35.5
TPH 251 251 176 291 510 25.0 36.0
TPH 277 277 176 291 510 27.0 36.5
TPH 302 302 176 291 510 27.5 37.0
TPH 352 352 186 398 570 32.0 54.0
TPH 402 402 186 398 570 36.0 56.0
TPH 508 508 186 398 570 40.0 59.0

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TPM (MEDIUM RATE TYPE)
Max. Dimensions (mm) Max. Weight Max. Weight
C5
Type Length Width Height (Unfilled) (filled)
(Ah)
(L) (W) (H) (kg) (kg)
TPM 10 10 48 81 245 1.2 1.5
TPM 15 15 48 81 245 1.5 1.8
TPM 20 20 68 134 245 1.6 2.5
TPM 30 30 70 134 245 2.0 3.0
TPM 40 40 70 134 285 2.8 4.0
TPM 50 50 70 134 285 3.2 4.2
TPM 61 61 80 141 370 4.2 6.0
TPM 71 71 80 141 370 4.5 6.4
TPM 76 76 80 141 370 4.6 6.5
TPM 81 81 80 141 345 5.0 6.6
TPM 86 86 80 141 345 5.6 8.5
TPM 101 101 106 164 345 6.5 9.0
TPM 122 122 106 164 345 7.2 9.5
TPM 142 142 164 167 345 8.5 13.0
TPM 152 152 164 167 345 9.0 13.2
TPM 163 163 164 167 345 9.5 13.5
TPM 203 203 138 276 420 13.5 20.0
TPM 254 254 138 276 450 15.5 22.0
TPM 275 275 138 276 450 16.0 22.2
TPM 304 304 162 200 450 17.5 23.0
TPM 351 351 162 200 450 18.5 24.0
TPM 355 355 162 200 450 20.0 25.0
TPM 386 386 138 276 490 21.0 26.0
TPM 406 406 138 276 490 22.0 27.0
TPM 508 508 176 291 510 28.0 40.0
TPM 612 612 176 291 510 30.0 42.0
TPM 719 719 186 398 570 42.0 58.0
TPM 826 826 186 398 570 45.0 60.0
TPM 913 913 186 398 570 47.0 62.0
TPM 1020 1020 186 398 570 50.0 65.0

TPL (LOW RATE TYPE)

Max. Dimensions (mm) Max. Weight Max. Weight
C5
Type Length Width Height (Unfilled) (filled)
(Ah)
(L) (W) (H) (kg) (kg)
TPL 10 10 38 84 128 0.6 0.7
TPL 17 17 32 113 223 0.9 1.2
TPL 20 20 32 113 223 1.0 1.21
TPL 22 22 32 113 223 1.1 1.25
TPL 26 26 32 113 223 1.15 1.3
TPL 31 31 68 134 245 1.7 2.55
TPL 41 41 68 134 245 2.1 2.85
TPL 46 46 68 134 245 2.4 3.0
TPL 51 51 68 134 245 2.5 3.2
TPL 61 61 68 134 245 3.2 3.6
TPL 71 71 80 141 370 3.8 5.7

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TPL 82 82 80 141 370 4.0 5.8
TPL 92 92 80 141 370 4.2 6.0
TPL 102 102 80 141 370 4.5 6.2
TPL 112 112 80 141 370 4.9 6.3
TPL 122 122 80 141 370 5.0 6.5
TPL 128 128 53 190 402 5.2 6.6
TPL 133 133 80 141 370 5.3 6.7
TPL 138 138 92 141 365 6.0 7.8
TPL 143 143 92 141 365 6.3 8.0
TPL 153 153 106 164 345 6.8 9.0
TPL 179 179 106 164 345 7.2 9.5
TPL 184 184 106 164 345 7.5 10.0
TPL 204 204 106 164 345 8.0 11.0
TPL 235 235 164 167 345 9.5 13.0
TPL 255 255 138 276 420 13.0 18.5
TPL 306 306 138 276 450 14.5 20.5
TPL 326 326 138 276 490 15.0 20.7
TPL 346 346 162 200 450 15.5 20.9
TPL 355 355 138 276 450 16.0 21.0
TPL 371 371 138 276 450 16.5 22.0
TPL 408 408 138 276 450 17.0 23.0
TPL 428 428 138 276 450 18.5 24.0
TPL 459 459 138 276 450 19.5 24.5
TPL 510 510 138 276 490 20.0 27.0
TPL 612 612 176 291 510 27.0 37.5
TPL 714 714 176 291 510 29.0 39.0
TPL 816 816 186 398 570 39.0 59.0
TPL 918 918 186 398 570 41.0 60.0
TPL 1020 1020 186 398 570 44.0 61.0

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 Precautions

It is assumed that only qualified personnel are engaged in assembly and installation of the
components provided.

Qualified personnel are persons who, on the strength of their training, experience and
instruction, together with their knowledge of the relevant standards, provisions, accident
prevention regulations and operating conditions, have been authorized by those
responsible for the safety of the components / installation, to carry out the relevant
necessary work, with the ability to recognize and avoid possible hazards. Amongst other
things, knowledge of First Aid and of local rescue equipment are also necessary.

Failure to observe the instructions on use, repair with non-original parts,

unauthorised intervention, or use of additives to the electrolyte shall invalidate the
warranty.

Safety instructions

The following safety measures relate to the handling of batteries and are to be observed in
connection with all operating instructions contained in these instructions.

Observe assembly and installation instructions and display visibly at point of

Installation.
Work on batteries only after instruction by qualified staff. The operating
instructions must always be accessible to personnel responsible for dealing with
batteries.

Wear eye protection and protective clothing when working with batteries..
Observe accident prevention regulations.

No smoking. No open flame, embers or sparks in the vicinity of the battery, to avoid
risk of explosion and fire.

Explosion and fire risk, avoid short-circuits.

Warning! Metal parts of the battery cells are always live. Never place foreign
objects or tools on the battery. Ensure adequate ventilation of the battery room, so
that explosive gases produced during charging are drawn off (i.e. DIN EN
50272-2).
Have eye rinsing bottle to hand. If electrolyte splashes into the eyes or onto the
skin, rinse with plenty of clear water and seek immediate medical advice.
Clothing contaminated with electrolyte is to be washed thoroughly.

Electrolyte is highly corrosive. In normal operation there is no possibility of contact

with the electrolyte. Electrolyte is released only if the cell housing is destroyed.

Do not tilt the battery

Use only approved lifting and conveying equipment e.g. lifting gear. Lifting hooks
must not cause damage to cells, connectors or connection cables.

Dangerous electrical voltage. Use only suitable tools and measuring instruments.

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 Chapter 1
Basic Knowledge on Alkaline Battery

1-1 Introduction

The two most popular types of storage batteries are Lead Acid and Alkaline batteries.
This instruction manual covers maintenance of the pocket type Nickel – Cadmium
Alkaline battery.
The alkaline storage battery provides easier handling and maintenance plus long – life
performance, as compared with a lead acid battery.
This instructions manual has been prepared to help you become familiarized with
construction and performance characteristics as well as proper maintenance
procedures of the battery.
Before using the battery, please read the instruction carefully.

1-2 Construction

No. Type Discharge Performance Applications

1. TPL Low discharge rate cell For emergency lights, train signals,
ships, emergency control power etc.
2. TPM Medium discharge rate cell For emergency power, operating
power of controlled
3. TPH High discharge rate cell For engine, starting gas turbine,
control system in power plant etc.
4. TSX Ultra high discharge rate cell For starting engine, inverter, AGV,
field to be needed much load at
short time etc.

(1) Unit Cell

1) Plate assembly
Main component unit of an alkaline storage battery cell is the plate assembly
consisting of a number of positive and negative plates.
Each plate, whether positive or negative, is practically of the same construction
except for active material, nickel hydroxide and graphite for the positive and
cadmium for the negative.
Several pockets, each made of finely perforated steel strips and filled with active
material, are mechanically put together to from a rectangular shape and then
trimmed with steel frames to make a sheet – like plate.
Several plates of the same polarity, properly spaced from each other, are
assembled on and suspended by a collector rod which is connected to an
electrode pole, thus making a positive or negative plate group.
Two groups of plates, one positive and the other negative, are then assembled
in such a way that positive and negative plates alternate i. e., negative – positive
– negative and so on.
The plates so assembled as above are separated and insulated from each other
by means of plastic rod separators and/or edge insulators.

2) Cell container
The plates assembly complex with electrode poles is housed in cell container
made either of stainless steel sheet or of plastic material.
Generally, plastic containers are used for a small – sized cell and stainless steel
container for a large – size cell.
For medium – sized cells, either plastic or stainless steel cell containers can be
used.

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 Plastic containers offer some advantages over stainless steel containers;
They are corrosion – free and permit observation of electrolyte level from
outside.
On the topside of cell containers are gas vent valves through which electrolyte is
added when required.

3) Electrolyte
Electrolyte for the nickel – cadmium alkaline storage battery is a solution of
chemically pure potassium hydroxide mixed with a small quantity of powder
lithium hydroxide in ion – exchange purified or distilled water.
For detailed information, see item 4-4 through 4-6.

4) Other parts
Most parts are made of nickel plate-plated steel except a few others made of
rubber or synthetic resin.
Therefore, the entire structure gives a high mechanical strength.

(2) Unit Battery

Two or more unit cells are put together in wooden or metallic box or tray to make
unit battery according to operating voltage requirement.
The cells of unit battery are connected in series with each other by means of
connecting bars.
The box or tray is usually provided with handle for carrying convenience.
The number of cells to be included in a unit battery is determined on the basic of
dimensions as well as weight of the component cell.
Two or more unit batteries can be connected to each other to make a larger battery
set when higher requirement should be met.

1-3 Chemical Reaction during Charge and Discharge

Active material for the positive plate is mainly composed of nickel hydroxide, which that
for the negative plate is mainly of either cadmium or cadmium hydroxide.
The electrolyte is an aqueous solution of about 22% potassium hydroxide with some
suitable additives.
The electrochemical reaction during charge and discharge is performed through
oxidation and reduction of the active material of the positive and negative plates.

CHARGE STATE DICHARGE STATE

2NiOOH + Cd + 2H2O → 2Ni (OH2) + Cd (OH)

←
(Pos. Plate) (Neg. Plate) (Pos. Plate) (Neg. Plate)

The electrolyte has very little to react directly with the charge and discharge except that
it acts as an electrical conductor.
For this reason, the specific gravity or concentration of the electrolyte remains
unaffected during the charge / discharge operation and therefore unchanged.

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1-4 Characteristics

(1) Capacity

Capacity of battery is, roughly, quantity of electricity available from a fully charged
battery when discharged at constant current.
Normally, it is indicated in ampere hour (Ah) and amounts to total Ah value of
discharging at specified constant current (one-fifth of capacity) over duration of 5
hours (5-hour rate discharge).
For example, It is normal for capacity of 100AH to last over 5 hours in 20A. But in
case of TSX (ultra high discharge rate cell)type, It is normal to last one hour. The
capacity is sometimes indicated in watt hour (WH), that is, product obtained by
multiplying ampere- hour value by average discharge voltage.

(2) Voltage

Open terminal voltage of unit cell is between 1.3 V and 1.5V, showing some
variation within this range, depending on how long a particular cell has been left
open- circulated after fully charged.
It also varies with charging condition, discharging current, temperature and type of
cell that has different internal resistance.
Nominal discharge voltage is 1.2V / cell in average for normal rate discharge.TPL
type has a comparatively higher internal resistance, therefore more suitably used
for low-rate discharge purpose. TPM type that has less internal resistance than
TPL type is used for medium-rate discharging while TPH, TSX type finds its
applications in high-rate discharge use.

(3) Relation between Discharging Rate and Capacity

Capacity varies with discharging current as indicated by Table 1, Discharging Rate

and Capacity. As you may notice in the Table, capacity obtained by the normal rate
discharge at 25℃is taken as 100% at 5 hours discharge time to 1.00 V/Cell final
voltage.

Table 1. DISCHARGING RATE AND CAPACITY

TYPE TPL TPM TPH TSX

Discharging Final Final Final Final

Capacity Capacity Capacity Capacity
Rate Volt Volt Volt Volt
(%) (%) (%) (%)
(C X AMP) (V/Cell) (V/Cell) (V/Cell) (V/Cell)
0.1 104 1.10 104 1.10 105 1.10
0.125 102 1.00 102 1.06 103 1.10
0.2 100 1.00 100 1.00 100 1.00 100 1.00
0.33 97 1.00 100 1.00 97 1.00 100 1.00
0.5 79 1.00 95 1.00 85 1.00 100 1.00
1 72 1.00 90 1.00 100 1.00
2 83 1.00 93 1.00
3 76 0.85 85 1.00
5 62 0.85 62.5 1.00

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 Chapter 2
Installation of Battery

2-1 Condition for Battery Room

The battery room which storage the battery must satisfy completely the following
ambient conditions
(1) Partitioned from other rooms
(2) Not exposed to the sun
(3) Air – conditioned, or protected form an excessive high room temperature in hot
season (desirable room temperature: 25℃)
(4) Well ventilated (a forced ventilation may be required)
(5) Adequately sloped floor for drainage of cleaning water, except the part to receive
the frame which must be correctly leveled, or designed to hold the frame leveled.

2-2 Unpacking and Inspection

(1) Visually check the packing for damage or evidence of excessive shock.

Cautiously unpack to protect the battery from excessive shock.

Be sure to unpack the battery near the battery room, and to transport cells by
holding the bottom of cell.

(2) Check the unpacked articles for the following items:

Quantity: Quantity of delivered items

Damage: Visually check deformation or damage of delivered articles.
If parts are missing or damaged, immediately contact transport or central office,
and take steps to procure missing or replacement parts

o Packages are clearly labeled with UP / DOWN mark.

o Do not turn the package upside down or up to side.
o Avoid excessive vibration or shock to the contents.
CAUTION

2-3 Filling Cells with Electrolyte

Cells are delivered empty of electrolyte, so that they should be filled with the electrolyte
when put in service.
Only those cells that are to be put in service very shortly will be filled with the electrolyte
and then given the first charging in accordance with Item 3-2 of this manual as soon as
possible after allowing enough time for the electrolyte permeate into the plate
assemblies of each cell.
More specifically, it takes four hours or so before the active materials in the plate
assemblies become sufficiently with the electrolyte and ready for the first charging.
If all or some of the cells delivered are not to be put in service for some time, keep them
properly in storage as instructed in Item 4-8.

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 (1) How to Fill

Using electrolyte jug and funnel supplied as maintenance tools, fill each cell with a
required amount of electrolyte in the manner as show in Fig 1.
For your safety, put on rubber gloves whenever you handle the electrolyte since it is
irritating to human skins and causes alkali burns on the skin contaminated if left
untreated.
Pour in electrolyte carefully to avoid possible overflow or spilling.

- First Filling-

Remove the transport seal from the cell vents.

Fill the cells slowly to level slightly above the low level mark.
Check the cells after 30 minutes and add electrolyte if the level has dropped.
Two hours after the first charge has been completed, add electrolyte to the
maximum level.

(2) How to Adjust Electrolyte Level

1) For stainless steel cell container (“ Not applicable”)

After completion of the procedures given in Item (1) above, adjust electrolyte
level of each unit cell to the normal level of_______mm above the plate top.
For the measurements, use the level test tube provided as an accessory.
For more details, refer to Item 4-3, topping up for stainless steel cell container
given in maintenance instruction for Pocket Type Nickel- Cadmium Alkaline
Storage Battery.

2) For plastic cell container

See – through type.
The plastic cell container permits one to see electrolyte level of each unit cell
from outside.
Slowly pour in the electrolyte until Maximum Level Mark.

2-4 Installation of Battery

(1) Installation of Steel racks

Steel racks, on which the battery is to be mounted and arranged, come completely
assembled for ready installation.
Place each steel rack I level position, so that each component cell or unit battery
may likewise be placed level.
Otherwise, the battery’s performance may be adversely affected.
Whether perfectly horizontal or not be easily detected by checking electrolyte
surface level against the level marks indicated on the plastic cell container.
Place a piece or pieces of thin vinyl chloride sheet or similar material under the rack
to hold the rack perfectly horizontal when such leveling is required.

(2) Arrangement of Battery

Now, mount each component unit battery onto the racks (s).
Carry each carefully by two persons or perhaps there, since it is now filled up with
electrolyte and pretty heavy.
Hold it as upright as you can when carrying.
The batteries should be correctly arranged and set up on the rack(s) in accordance
with the Wiring Diagram taking special care to avoid possible polarity confusion.

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(3) Connections
Using appropriate connecting bars supplied as accessories, connect component
unit batteries in series to each other as show in the reference Wiring Diagram.
Tighten each connection by means of appropriate pole nut spanner, supplied as an
accessory.
For safety, make the battery set open – circuited when connecting it to battery
charger.

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 Chapter 3
Initial Charging and Storage

3-1 Pre-charge Preparation

Installed and connected properly as above, the battery should be fully charged as soon
as possible.
Before proceeding to charge it, however, check the A. C. power source and the battery
charger to make sure they are in normal condition.
Also measure voltage of the entire battery and each cell, specific gravity and
temperature of electrolyte to make sure there is no irregularity.
Now connect the (+) terminal of the battery to the (+) terminal of the battery charger and
the (-) to the (-) for the charging.

3-2 Charging Procedures

The standard charging current for each model of the batteries is show in Table 2 below.

TABLE 2 CHARGING CURRENT

CHARGINGCURRENT CHARGING TIME

MODEL CAPACITY
(5-hr. rate, Amp.) (Hr)

EXAMPLE

TPL 102 102 20.4 (102 x 0.2) 12

TPM 101 101 20.2 (101 x 0.2) 12

TPH 101 101 20.2 (101 x 0.2) 12

TSX 100 100 20 (100 x 0.2) 12

(1) As indicated above, the charging should be continued for 12 hours with the
above-indicated constant current. (Refer to Instruction Manual for Charger.)

(2) Cell voltage gradually rises with progress of the charging, so that it is necessary to
raise the rectifier’s output voltage accordingly by means of its manual output
voltage regulator in order to maintain the charging current constant at the specified
rate.

(3) In the course of charging, the electrolyte temperature also rises, however slowly. If
the temperature rises above 45°C, it is detrimental to the battery.
In such a case, suspend charging temporarily and then resume it again after the
temperature has dropped sufficiently.

(4) A recording form like one shown in Table 3 is a must when charging the battery.
Record all particulars about the battery as the charging progresses.

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 TABLE 3 RECORDING FORM (Example)

Customer: Order No.:

Installed location:

Installed Date:
Supplier:

Battery No.:
Cell type: No. of cells:
Capacity [Ah]:

Charging method:

€ €
Constant voltage (U- or IU characteristic) Constant current (I or Ia characteristic)

Constant voltage [V]: Constant current [A]:

Maximum current [A]: Maximum voltage [V]:

Battery voltages:
Charging voltage [V] Start of charging: end of charging:
Open-circuit voltage [V] Start of charging: end of charging:

Charging current:
Charger current [A] Start of charging: end of charging:

Temperatures:
Ambient [°C] Start of charging: end of charging:
Electrolyte [°C] Start of charging: end of charging:
Pilot cell [°C] Cell-No.:

Charging time:

Date from: to:

Time from: hours to: hours

Commissioning carried out by:

Date, signature

Acceptance (supplier) carried out by:

Date, signature

Acceptance (customer) carried out by:

Date, signature

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Measurement of individual cell voltages 1-120:

Cell 1* 2* 3* Cell 1* 2* 3* Cell 1* 2* 3*

No. [V] [V] [V] No. [V] [V] [V] No. [V] [V] [V]
1 41 81
2 42 82
3 43 83
4 44 84
5 45 85
6 46 86
7 47 87
8 48 88
9 49 89
10 50 90
11 51 91
12 52 92
13 53 93
14 54 94
15 55 95
16 56 96
17 57 97
18 58 98
19 59 99
20 60 100
21 61 101
22 62 102
23 63 103
24 64 104
25 65 105
26 66 106
27 67 107
28 68 108
29 69 109
30 70 110
31 71 111
32 72 112
33 73 113
34 74 114
35 75 115
36 76 116
37 77 117
38 78 118
39 79 119
40 80 120

1* = open terminal voltage

2* = end-of-charge voltage 15 min before end
of charging
3* = cut-off voltage after 5 hours discharge

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Measurement of individual cell voltages 121-240:

Cell 1* 2* 3* Cell 1* 2* 3* Cell 1* 2* 3*

No. [V] [V] [V] No. [V] [V] [V] No. [V] [V] [V]
121 161 201
122 162 202
123 163 203
124 164 204
125 165 205
126 166 206
127 167 207
128 168 208
129 169 209
130 170 210
131 171 211
132 172 212
133 173 213
134 174 214
135 175 215
136 176 216
137 177 217
138 178 218
139 179 219
140 180 220
141 181 221
142 182 222
143 183 223
144 184 224
145 185 225
146 186 226
147 187 227
148 188 228
149 189 229
150 190 230
151 191 231
152 192 232
153 193 233
154 194 234
155 195 235
156 196 236
157 197 237
158 198 238
159 199 239
160 200 240

1* = open terminal voltage

2* = end-of-charge voltage 15 min before end
of charging
3* = cut-off voltage after 5 hours discharge

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3-3 After – care of initial Charging

If the battery, after given the complete first charging, has discharged more or less due
to various tests involving load, it should be charged again with the 10 – hour rate
current for 14 hours before put in actual service.

At the end of each charging, check each cell for proper electrolyte level. If
the battery is found considerably lower then max electrolyte level mark,
NOTICE add distilled or ion – exchange purified water until the proper level is
restored.

3-4 Storage of Charged Battery

If the battery that has become fully charged through the first charging is not put in
service immediately, it should be handled as instructed in the following.
A charged storage battery is subject to a gradual loss in capacity due to self –
discharge even when left unused.
If the battery is to remain unused for a period of 6 months or more after fully charged,
you should refer to Item 4-8 of this manual for its proper storage.
If the battery is not be put back in service following less than 6 months of storage, it
should be recharged fully every three months with the10-hour rate current for 14 hours.

- 17 -
 Chapter 4
Maintenance

4-1 Charging

A storage battery is charged with DC (direct current).

For charging, be sure to connect (-) pole of the battery to (-) terminal of the charger and
(+) pole to the (+) terminal.
For normal charging an alkaline storage battery is charged with 5-hour rate current for
7 hours.
This equals to 140% of the nominal capacity.
In other words, Ah efficiency of the alkaline storage battery is 71.5% of total amount
electric current put in for complete charging.
That is why an alkaline storage battery is usually charged for 140% of the discharging it
was subject to.
Whether or not an alkaline storage battery has been completely charged cannot be
judged by measuring the specific gravity of its electrolyte.
The battery is deemed to have been fully charged when an additional 2.5 to 3 hours of
charging was completed after the charging voltage had risen to constant 1.65 – 1.80 V
/ cell during the charging.

(A) Floating Charge

When a battery is connected in parallel to both the rectifier and load for use as an
auxiliary power source, it is kept charged with a small but constant current to
automatically cover capacity loss resultant from self –discharge or other
discharges imposed upon it during such use.
This is called Floating Charge.
When connected to a Floating Charge, the battery is kept in fully charged state so
that it may be readily used as auxiliary power source when a commercial power
failure or voltage drop occurs.
Floating Charge voltage is normally 1.40 to 1.50 V per cell and the ampere is
about 1 / 40 of 5- hour rate current (1 /200 C).
These values should be adjusted properly according to conditions under which the
battery is in service; too much gassing or water consumption means the charging
voltage is too high, whereas a gradual drop of capacity indicates the charging
voltage is too low.

4-2 Influence of Temperature

Temperature is one of the factors affecting performance of a storage battery.

Electrolyte temperature most suitable for charging is from 68 (20℃) to 77 (25℃).
Usually, the temperature of electrolyte in a cell gradually rises with the progress of
charging, but an excessively high temperature above 113 (45℃) can affect the life of
the battery.
So please take care that the temperature of the electrolyte does not exceed the
permissible limit during charge.
Nevertheless this battery is capable of withstanding an electrolyte temperature of 122
(50℃), the highest temperature limit, for short periods of time and sustained electrolyte
temperature of up to 113 (45℃) without damage or undue loss of capacity.

4-3 Topping Up of Electrolyte

The water electrolysis and evaporation constantly taking place in the cell, slightly
lowers the electrolyte level in the cell.

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This is the reason why topping up of electrolyte is needed from time to time in order to
keep the surface level between the Min. and Max. level marks or between the plate top
and Max. surface level.

(A) For Plastic Cell Container

Each cell has two level marks, Maximum and Minimum.

A transparent container, it allows one to check the electrolyte level visually from
outside with your own eyes.
The electrolyte level should be kept between these Max. and Min. level marks.
Top up with distilled or ion- exchange purified water when necessary.

(B) For Stainless Steel Cell Container (“ Not applicable”)

1) Inspection of Electrolyte Solution Height above Plate Top:

As show in Fig. 2, insert into the cell through the filler vent the inspection tube
with its graduated part down and stand it upright on the plate top.
Now, as show in Fig. 3, pressing the top end of the tube from above with your
index finger or thumb, pull it out of the cell.
The solution height retained in the tube indicates the height above the plate
top in the cell.

2) When to Top Up:

To ensure against possibility of the electrolyte level falling below the plate top
of the cell topping up should be carried out when the cell’s electrolyte level
comes down as low as one third the standard solution height.
To be more specific, the topping up must be made when the electrolyte level is
less than _______mm in height from the plate top since the standard
electrolyte height prescribed for the cell is________mm above the plate top.

Usually, distilled water or ion – exchange purified water is used for the topping
up the electrolyte.

3) How to Top Up:

The topping up of the electrolyte can be done easily with the spout – like level
inspector provided as an accessory.
(See Fig. 4)
Its nozzle has been made to such a length that nozzle tip may exactly reach
from the filler top to the surface of the solution filled to the standard height.
So, take into the spout as much distilled water or ion – exchange purified water
as it can hold a simply insert it into the cell as show in Fig.4 until the proper
solution height is obtained.
To determine the nature of routine maintenance works needed in normal
service and proper time intervals between the inspections or maintenance
works, it is important that these are conducted at short intervals, say, once a
month or so, during the earlier months of the service, while recording the
results and reviewing them carefully at each occasion.
This will reveal specific trends of the battery, on the basis of which it is possible
to determine more accurately the nature of, and time intervals for,
maintenance work and inspection are actually needed less frequently than
generally assumed.
A larger amount of charge accelerates loss of the water from the cell.
Be sure to refill the cell before such a charge or recharge.

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4-4 Preparation of Electrolyte

The electrolyte for Alkaline Storage Battery is a solution of chemical pure potassium
hydroxide (commonly know as caustic potash) mixed with powder lithium hydroxide
dissolved in ion-exchange purified or distilled water.
We furnish the electrolyte.
It comes in solid, dry tablet state and contained in a sealed vessel.
Special attention should be paid to ensuring that only pure electrolyte is used.
Otherwise, the cell may be injured permanently.
Dissolve the electrolyte little, maintaining the 1 to 4 ratios in weight between the
electrolyte and the water.
The properly prepared solution should have the 1.20/ 20°C specific gravity.
Regulate the solution to the proper specific gravity1.20 / 20°C by adding water or the
electrolyte as appropriate.
Some electrolyte solution shows different specific gravity values at different
temperatures; lower at higher temperature and higher at lower temperature.
Specific gravity at 20°C is taken as standard, from which it increases by 0.0005 per1.0
drop from 20°C and decreases also by 0.0005 per 1 rise above 20°C.
While the standard specific gravity of the solution is set forth as 1.20 / 20°C, the specific
gravity ranging form 1.16 to 1.23 at 20°C is allowable.
Beyond 1.23, the cell may be harmed and below 1.16, it will fail to act at the rated
capacity.
For electrolyte handling, use a vessel of glass, porcelain steel, anti – alkaline plastic,
nickel or stainless.
Never use for electrolyte handling that of copper, aluminum, celluloid or wood, which
be corroded by the alkaline electrolyte.

The electrolyte readily absorbs carbon dioxide from the air, consequently
forming potassium carbonate, the presence of which in the electrolyte
causes poor output of the cell.
NOTICE So keep the electrolyte in an airtight can to avoid the contamination
caused by the absorption of carbon dioxide form the air.

4-5 Caution on Handling of Electrolyte

The electrolyte is irritating to the skin and destroys clothing stained with it.
Alkali burns may cause serious inflammation on the skin it left without proper treatment.
In an emergency obtain medical treatment as soon as possible.
Alkaline effect is neutralized with a light acid such as vinegar or boric acid (3%).

4-6 Renewal of Electrolyte

The density of the electrolyte slowly decreases with a gradual loss of alkali caused by
gassing taking place in the cell or by accidental spilling of the solution.
The electrolyte may also be contaminated with various impurities in the course of
normal use.
This makes it necessary to renew once every five to six years will be enough, and in the
course of this period the specific gravity will have fallen to the lowest limit.
The effects of impurities in the electrolyte causes poor output of the cell.
The maximum permissible limit is 100 g per litter.
Other acid radicals such as sulfate also have adverse effects on the positive plate.
The metal impurities more positive than copper would deposit on the negative plate
and lead to a continuous self discharge.
When the specific gravity of the electrolyte has fallen to the lowest permissible limit or
impurities have accumulated in the electrolyte beyond limit permitted, the electrolyte

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 must be renewed immediately.
Before renewed of the electrolyte, the battery should be discharged to 0.6-0.8 volts per
cell at 5- hour rate current (C/5).
After having discharged as above, open up the filler cap, insert a siphon into each cell
through the filler tube and drain off the old electrolyte completely.
Now, fill up each cell with the new electrolyte for too long nor rinse its interior with
water.
For renewal of the electrolyte, usually use the Type B-10, which will be dissolved to
provide 1.20 ± 0.01 specific gravity.
Electrolyte, B-10 or A only, should be used for the renewal.

Please renewal the electrolyte in the cell when:

1) The specific gravity of it has fallen below 1.16
2) The Cell fails of work at the rated capacity
3) The impurities in the electrolyte have accumulated beyond the permissible limit or
foreign materials (especially heavy metals).

The battery with its electrolyte renewal completely will restore the rated capacity when
given the following charge and discharge treatment without being connected to the
load.
Before the charge and discharge, close the vent valve, clean each cell and make sure
all cells are put I plate, properly connected as they were before.
1) Charge the battery for 10 hours at 5-hour rate or 20 hours at 10-hour rate (200%
charge for rated capacity).
2) Discharge the battery at 5-hour rate to 1.0V/cell level.
3) Charge it again as 1) above and it will be ready for use.

Check all cells for proper electrolyte density and level after the charge.
NOTICE

4-7 Cleaning

The battery will provide better and longer service if kept clean.
Dirt and other foreign materials deposited on the battery will cause current leakage.
The cell top is apt to be moistened with electrolyte.
So, take care to kept it clean and dry since dirty and wet contacts will also cause
leakage of current.
Do not use sand paper or emery cloth on nickel- plated parts since they will damage the
nickel plating, resulting in increased resistance and rusting.
In particular, observe following practices for proper maintenance.
A little caution in daily maintenance will save a great expense in future.

1) Clean the outside of this battery, especially cell top and pole assemblies at least
once month. Apply a sufficient quantity of anti-rust oil (Supplied by us) or Vaseline to
the nickel – plated parts.
2) Tighten poles and other connections now and then.
3) Avoid using solder and similar materials for repair for repair of the battery

4-8 Storage of Battery

To keep the battery in storage for a long period of time, namely, 6 months or more, it is,
first of all, necessary to discharge it completely and remove the electrolyte also
completely.

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 For such and extended period of battery storage, discharge the battery to 0 V and
remove the electrolyte from all the cells and then close the vent plug of each cell.
Be sure to store the battery in room that is clean, cool, dark and dry.
To put the battery back in service, fill every cell with the electrolyte properly as
instructed previously and then charge it fully by following the same procedure for the
first charging explained in Chapter Ⅲ.

4-9 Regular Maintenance and Inspection

A battery gives optimum performance and longer life when given proper maintenance.
Therefore, it is important to inspect it periodically and record its conditions by jotting
down the results found at each inspection.
Should something unusual be found, find out the cause therefore as soon as possible.

(A) Floating Charge Voltage

Floating charge is a way to supply load with electric power from battery in case
of blackout or load fluctuating. For that case, battery must keep in good condition,
be permitted appropriate floating charge voltage. Connect battery and load to
charge device in parallel system and regular voltage must always be permitted for
charge. Longevity and efficiency of battery depends on voltage figure to be set up
in floating condition.
If the figure is lower than the one required, It results in shortage of charge and
long period of this condition causes decrease of longevity on account of
inactivation made by active material of the positive and the negative pole. On the
contrary, If the figure is higher than the one required, It results in over-charge and
causes decrease of longevity as well due to deterioration of Isolated plates or
corrosion of the positive and the negative pole. Inner resistance makes the voltage
difference between a type of battery and other types. The error range of battery
voltage is ±5% settled by experiences of each manufacturer but it does not mean
a permitted range for charger.Refer to TABLE 4 to set up floating charge voltage.

Total floating charge voltage is obtained by multiplying the standard per – cell
voltage by the number of cell very long due to no occurrence of AC power failure or
other situations that required the battery to discharge.

(B) Equalizing Charge

Equalizing charge is a way to prevent floating charge voltage from getting out of
its figure to be set up that results from self-discharge. That is why several batteries
are used for long time as a group for equalizing charge. Normally, equalizing
charge is required once every 6 months and it does not need to be strictly abided
by.

The TABLE 4 below is normal voltage for it.

FLOATING CHARGE EQUALIZING CHARGE

TYPE
VOLTAGE VOLTAGE

TPL 1.40 ~ 1.45 1.55 ~ 1.60

TPM 1.40 ~ 1.45 1.55 ~ 1.60

TPH 1.40 ~ 1.45 1.55 ~ 1.60

TSX 1.38 ~ 1.40 1.46 ~ 1.48

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The total charge voltage is settled by multiplying the number which constitutes normal
battery voltage. After equalizing charge, surly being switchover to floating charge
voltage automatically. If it does not happen, it results in overcharge and causes
decrease of longevity and capacity due to evaporation of electrolyte. Therefore certain
checking is required for the switchover.

(C) Check Points at Inspection

1) Checking points every one month

METHOD TO
ITEM CONTENTS STANDARD
SOLVE

1. Total voltage of Check the instruction Charge voltage × Number adjust in case of getting
battery in of the voltage figure of battery indicated in out of the standard
floating charge on the panel of a TABLE 4 voltage indicated in
voltmeter TABLE 4
2. Electrolyte level Check electrolyte Surly placed within the Check the leakage of
level if it is placed range of minimum and electrolyte and fill up
within the standard maximum level electrolyte to the
required or not maximum level if
necessary
3. Appearance of Check the leakage of Clean according to Item
battery electrolyte 4 - 6. If the leakage of
electrolyte does not
stop, contact us

2) Checking points every six month

METHOD TO
ITEM CONTENTS STANDARD
SOLVE

1. Total voltage 1) Measure 1) Total voltage of battery 1) Adjust in case of

of battery in total voltage of is Floating charge measured voltage's
floating charge battery with a voltage x number of getting out of the
voltmeter cell shown in TABLE 4 standard voltage
2) Check the 2) Repair or replace
instruction of the battery which
voltage figure on exceeds the
the panel permitted error
2. Voltage of each Measure the voltage Surly place voltage If measured voltage is
cell in floating of cell with a of every cell within the lower than the standard
charge voltmeter range of ±5% shown in voltage, do equalizing
TABLE 4 charge shown in
TABLE 4 and compare
the result with the
standard voltage again.
If the result differs from
the standard voltage
after equalizing charge,
contact us
3. Electrolyte level Check electrolyte Surly placed within the If electrolyte level is
level if it is placed range of minimum and placed around or below
within the standard maximum level the minimum level, fill
required up electrolyte to the
maximum level

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ITEM CONTENTS
4. Appearance of Damage or leakage
battery of electrolyte caused
by transformation of
crack on the lid,
cover etc.
Pollution & damage
caused by dirt etc.
Rust on the cubicle,
holder, connecting
plate, connecting line
and terminal
Damage on the
various kinds of
stopper and packing
METHOD TO
STANDARD
SOLVE
1) Contact us if crack,
damage,
transformation are
found
2) Clean according to
Item 4 - 6, if leakage
of battery happens.
Contact us if it lasts
constantly long time
Clean polluted points
with wet Cloth
Cleaning, coating and
repairing needed
Contact us if any
damage is found

3) Checking points every one year

Checking points every one year adds checking points every six month to the
particulars below.

METHOD
ITEM CONTENTS STANDARD
TO SOLVE

Specific gravity & Measure electrolyte 1) Specific gravity must be 1) Adjust specific gravity
temperature in & temperature in within the range we within the range
Pilot Cell in floating Pilot Cell indicate indicated
charge 2) Temperature must be 2) Set 20°C as the
below 25°C as much as standard of specific
possible gravity and measure
with a hydrometer
and convert with the
following formula

S20 = St + 0.0005 (t - 20)

S20 : Specific gravity
converted by 20°C
St : Specific gravity
measured at t°C
t : Temperature of
electrolyte(°C)

( Pilot Cell is selected optionally as a standard among compounded

cells )
NOTICE

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4-10 Disposal

Disassembly and disposal of the battery should be carried out only by trained
personnel. EC Directives 91156 (EEC) and 9386 (EEC) must be observed. Your local
TECHFILL representative will be pleased to give you a quotation for proper
disassembly and disposal of your battery.

Further action, in particular the operation and maintenance of the

battery, is described in the instructions “TECHFILL INSTALLATION
AND INSTRUCTION MANUAL For POCKET TYPE NICKEL-
CADMIUM ALKALINE STORAGE BATTERY”. It is essential that these
instructions, which are supplied with the battery, are followed.

Used batteries with this symbol are recyclable goods and must be sent
for recycling. Used batteries which are not sent for recycling are to be
disposed of as special waste under the appropriate regulations.

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