Exide Technologies GB3565 User Manual

KDZ

RAILWAY DIESEL STARTING
BATTERIES

INSTALLATION AND OPERATING INSTRUCTIONS

CAUTION - READ THE ENTIRE INSTALLATION AND OPERATING INSTRUCTIONS BEFORE PLACING BATTERIES IN SERVICE.

1 . SAFETY

1.1 Follow your company’s Safety Instructions
when working with or near diesel starting
batteries. Observe the caution label affixed
to the battery. Thoroughly familiarize yourself
with industry and government guidelines
(OSHA, ANSI) for charging, handling and
maintaining diesel batteries.

1.2 Assign battery and charger care to properly
trained personnel.

1.3 This battery contains sulfuric acid. Avoid
contact with skin, eyes, or clothing. Wear
rubber apron, gloves, boots and goggles or
face shield when handling, checking, filling,
charging or repairing batteries.

1.4 Keep water readily available for flushing
spilled electrolyte from eyes or skin. Use
plain water only and obtain medical attention
immediately. Special deluge showers and
eye wash basins are required.

1.5 Batteries produce hydrogen during charge.
Keep open flames away. Do not check
electrolyte level with a cigarette lighter or
match. Use a flashlight or permanent lights.
Do not smoke or create sparks.

1.6 Lift batteries with a hoist, crane, lift truck,
or similar equipment. Move batteries on
trucks, conveyors or rollers. Be sure to place
a rubber mat or similar insulating material
across tops of batteries without covers when
handling. Make sure equipment is of ample
strength and properly installed.

CAUTION: Do not use chain or wire rope slings.

1.7 Never lay metal tools, such as wrenches or
other material on top of a battery.

1.8 Disconnect the battery from the locomotive
when performing maintenance and repair
on the motor or electrical system.

1.9 Open or “break” the battery circuit before
attempting repairs to terminal connections.

1.10 Apply a strong neutralizer, like baking soda,
when acid is spilled on the floor. Check local
regulations regarding disposal of neutralized
waste.

2. RECEIVING BATTERIES

Immediately upon receipt of shipment, examine
the outside of the packing for signs of rough
handling before accepting battery from carrier.
Wet spots on the shipping pallet may be an
indication of leaking jars broken in shipment.

If there is evident damage, the receipt should be
signed and both copies (carrier’s and receiving
copies) marked “Shipment Received Damaged”.
The carrier should be called immediately and
asked to make a “Carrier’s Inspection for Damage
Report”.

If “concealed” damage is later detected, the carrier
should be called immediately and requested
to make a “Carrier’s Inspection for Concealed
Damage Report”. After inspection by the carrier,
arrangements should be made with the local

®

Industrial Power representative to have

GNB
the battery repaired before placing it in service.

CAUTION

Before placing a battery in service,

review and adhere to the Safety

Guidelines listed in Section 1.

3. INITIAL FRESHENING CHARGE

Remove the vent caps from each cell and check
to see that the electrolyte level is above the plates.
During shipment of the battery, low temperatures
and/or normal shock and vibration often results in
a drop in the electrolyte level. If the level is below
the plates, recheck it after three hours of charging.
If the level remains below the plates, add water
until the plates are covered. If it is obvious that
electrolyte has spilled out of any cells, replace
it with electrolyte of the same specific gravity as
found in the other cells of the battery.

Replace the vent caps and give the battery a
freshening charge of 3 to 6 hours or by continuing

the charge until there is no increase in specific
gravity for three hydrometer readings taken at
one hour intervals. CONTINUE CHARGING

AND MAKE FINAL ADJUSTMENT OF THE
ELECTROLYTE LEVEL TOWARD THE END OF
THE CHARGE.

Upon completion of the freshening charge, the
normal fully charged specific gravity should be

1.245 to 1.255 at 77°F.

is indicated by decreasing electrolyte specific
gravities.

The correct operating or battery float voltage to
be set on the regulator is that which will maintain
the battery in a fully charged condition. This
correct setting depends on two factors—operating
temperature and locomotive work schedule. It is
recommended that voltage regulator adjustments
be made while the engine is at operating speeds.

4. INSTALLING BATTERY (BLOCKING)

Negligence in properly blocking a battery in the
compartment is apt to permit shifting and may
cause damage. All trays should be securely
blocked, but care should be taken to avoid
overtight wedging. Clearance of about 1/8" should
be left between the blocking and the battery trays.

5. TERMINAL CONNECTIONS

Make
in-lb. Inspect terminal connections regularly
and keep them clean and tight to 100 in-lb.

6. VOLTAGE REGULATOR

The battery is only one part of a total system,
all of the parts of which are inter-related and
interdependent. The battery simply stores energy
in a chemical form for use when the generating
system is not running. It is not a source of power
but merely a reservoir. The battery supplies power
for starting but, as soon as the engine is running,
the generating system must replace the power
withdrawn from the battery.

Input from the generating system to the battery is
controlled by the voltage regulator. It is important
to make sure that the regulator is known to be in
satisfactory operating condition and adjusted to
the correct operating voltage.

If the voltage regulator is not in good operating
condition or is adjusted to an incorrect operating
voltage, the battery will not function satisfactorily
because the charge it receives will be insufficient
(undercharged) or excessive (overcharged). In
severe cases of bad regulation and overcharging,
failure can take place within a year. Overcharge
is indicated by faster water loss than normal.

A bad regulator or one set too low can cause
undercharge—a condition which will literally
starve the battery to death. In this case, more
power is drawn out of the battery than is replaced.
As a result, the battery gradually runs down until
it is so low that it fails completely. Undercharge

original connections clean and tight to 100

Correct battery float voltage at different
environmental temperatures are as follows:

Float Voltage

Temperature (Volts/Cell)

Greater than 80°F 2.25-2.30
50°F to 80°F 2.30-2.33
Less than 50°F 2.33-2.38

The effect of locomotive work schedule on
the correct float voltage is determined with
experience. If a battery is used for starting
very frequently, float voltages should be set at
the higher end of the range indicated at the
appropriate temperature; similarly, for infrequent
battery usage, float voltages should be set at the
lower end of the range.

7. VENTILATION

As explained in Section 2, gases produced
from a charging battery are explosive! Clean all
ventilating openings to remove any collection of
dirt or dust that might prevent the free circulation
of air.

8. WATER ADDITION

All lead acid batteries, in the course of normal
operation, generate hydrogen and oxygen from
water in the electrolyte.

Gassing or water consumption in a battery
is a function of float voltage and operating
temperature. Excessive water consumption
indicates the voltage regulator setting is too high
and should be reduced. Normally, it should not
be necessary to add water to the battery more
than once every 30-180 days in the summer and
once every 60-180 days in the winter.

If the gravity reading shows a continual lowering,
or consistently remains 10 to 20 points below the
fully charged gravity, the voltage regulator is set
too low for the locomotive’s work schedule and
it should be increased to allow more charge. Do
not increase or decrease the voltage regulator
setting more than 1/2 volt at a time. Recheck

the battery after each adjustment to see if an
additional change in regulator setting is necessary.

battery is fully charged and the electrolyte
level is at the maximum.

The maximum electrolyte level, with the battery
on charge, is at the bottom of the vent well. It
should always be maintained between there
and the top of the plates. However, such things
as cold temperature or extended open circuit
stands will cause the level to drop without the
loss of electrolyte or water from the cells. Under
these conditions, do not adjust the level without
first charging the battery for 3-6 hours. Before
charging, make sure the electrolyte covers the
plates. Otherwise, electrolyte overflow may result.

When adding water, always use distilled water
or water that is known to be free of abnormally
high amounts of impurities. Contact GNB or your
local Sales Representative if you are not sure of
your water quality.

9. ADDING ACID

Acid should be added to a cell only when
electrolyte is spilled or otherwise not returned.
Always add acid of the same specific gravity as
that in the cell and only in the same amount as
was lost from the cell. To increase the electrolyte
level in the cell, use water at all times.

10. SPECIFIC GRAVITY

Read the specific gravity of the electrolyte
BEFORE adding water, otherwise the reading
will be low. Return all of the electrolyte to the cell
from which it was taken.

a) Effect of Temperature on Specific Gravity:

Variations in temperature affect the specific
gravity of the electrolyte and temperature
corrections should be made. One point
(.001) should be added to the hydrometer
reading for each 3° above 77°F and one
point should be subtracted for each 3° below
77°F. Make a record of the reading.

b) Effect of Electrolyte Level on Specific

Gravity:

11. CLEANING

Keep the vent caps in place during use and
charging. Remove them only to observe levels,
make water additions, take temperatures, or take
specific gravity readings with a hydrometer. The
battery can be washed off with water if dusty.
Keep the vent caps in place. If electrolyte has
accumulated on the top of the battery, wash
with an approved neutralizing solution, available
through GNB service. Follow the wash with a rinse
using clear water. Dispose of all waste materials
in an environmentally safe manner.

12. STORAGE OF SPARE BATTERIES

a) General Care:

Spare charged (wet) batteries should be
given regular good housekeeping care. A
clean, cool, dry place, free from dust and
debris, should be selected for storage space.

b) Testing:

Spare charged (wet) batteries should be
checked quarterly to determine the specific
gravity. Batteries should be charged when
the specific gravity drops thirty (.030) points
below the specified fully charged reading.
Temperature affects the need for charges.
Usually a charge is required every three
(3) months.

c) Charging:

When charging is required, use the Finish
rate. (See name plate for Finish rate.)
Continue charging until gassing occurs.
Charging should not be discontinued until
the temperature-corrected specific gravity
of the lowest cell has risen to the maximum
and has shown no further rise for two (2)
consecutive hourly readings.

Variations in solution height affect the
specific gravity of the electrolyte. Normally
water is consumed in the operation of a
battery and electrolyte levels will decrease,
causing a slight increase in specific gravity.
For every 1/8" decrease in electrolyte level of
these batteries, there will be an approximate
increase of .003 in specific gravity. The
specific gravity should be 1.250 when the

13. REMEMBER THESE IMPORTANT FACTS

For maximum battery life and performance,
always be aware of these potential problem areas
and take the appropriate action to correct them
should they occur.

SHORT CIRCUITS—cause electrical leaks

that run batteries down.

ENERGY WASTE—running battery down
with lights or accessories unintentionally left
on when engine is not running.

POOR, DIRTY CONNECTIONS—corrosion
builds up resistance which impedes—often
stops—the flow of power to and from the
battery .

LOW REGULATOR SETTINGS— limit the
flow of recharging current to the battery
thereby starving it.

HIGH OR UNCONTROLLED REGULATOR—
permits excessive flow of current to the
battery causing excessive loss of water and
premature failure.

14. WARRANTY AND RECORDS

Diesel starting batteries are warranted against
manufacturing defects or factors under GNB
Industrial Power control. There are many factors
under the control of the battery user that can damage
the battery. The most important user-controlled

factor is the battery float voltage set on the voltage
regulator of the locomotive generating or charging
system. Many battery users routinely keep records
of monthly readings of voltage regulator output
with the engine at idle and at operating speed. As
explained above (Section 6), the correct adjustment
of battery float voltage is critical in ensuring battery
performance. To keep the warranty valid, the
following records must be kept:

a) Quarterly record of voltage regulator output

or battery float voltages together with the
temperature range for which adjustment is
made; and

b) Quarterly log of electrolyte level and specific

gravity in the cells of the battery. Such records
can alert the user to the existence of abnormal
conditions in his application that can adversely
affect the battery. Preventive actions can then
be taken promptly to ensure the battery is not
damaged.

15. RECYCLING

U.S. Federal and State Regulations require that lead
acid batteries be handled and disposed of in compliance
with strict guidelines. GNB offers disposal service for
lead acid batteries. Call 1-888-438-5865 to arrange a
pick-up or to get additional information. In Canada, call
1-800-231-9081.

In the USA, call 1-800-GNB-RAIL for additional information.
In Canada call 1-800-268-2698 for additional information.

For alternate language versions of this document, visit www.gnb.com

POST THESE INSTRUCTIONS

IN BATTERY MAINTENANCE AREA

GNB Industrial Power

U.S.A. - Tel: 877.GNB.INFO
Canada - Tel: [phone]

www.gnb.com

GB3565 2013-10

A Division of Exide Technologies