TATA AUTOCOMP GY BATTERIES LTD

Continuously Raising The Bar

 INTRODCUTION TO BATTERY

Basic of Electrical.

What is Battery & Battery Types

Battery Construction

Battery Nomenclature & Governing Standards

Layout & Terminals Identification

Bar Codes

Continuously Raising The Bar

 Basics of electrical
• Voltage-:(Volt) In order to have a flow of water in a pipe pressure is necessary ,
likewise in order to have an electricity flow in an electrical system or wire ,pressure is
also necessary. In electricity the force or potential that pushes electricity is
called voltage. Electrical pressure (Voltage) is measured in volt ‘V’.

• Ampere-: This can be described as amount of water flowing in the pipes which is
measured in liters per minute hence electricity flowing in an electrical system is
current which is measured in amperes (A)

• Resistance-:(Ohm) The diameter of a pipe determines the amount of water that can
flow through it in a given time .Smaller the diameter of pipe more will be the
resistance. A smaller pipe provides more resistance to the flow of water.There is also
resistance to electron flow in electrical system. Resistance is the opposition offered
by a material to the free flow of electrons. The unit of resistance is called in Ohms.

Continuously Raising The Bar

Relationship between Voltage, Resistance and current

Continuously Raising The Bar

 What is Battery

A battery is a device that stores energy for later use

where in chemical energy is converted into electrical
energy.

Common use of the word, "battery," however, is limited

to an electrochemical device that converts chemical
energy into electricity

A battery consists of one or more cells connected in

series or in parallel

Continuously Raising The Bar

 Types of batteries
(TGY Product Portfolio)

Primary Battery (Chemical

Reaction irreversible)

• A primary battery is a battery

that is designed to be cycled
(fully discharged) only once and
then discarded

Secondary Battery (Chemical

Reaction reversible)

• A secondary battery is
commonly known as a
rechargeable battery. It is
usually designed to have a
lifetime of between 100 and
1,000 recharge cycles,
depending on the composite
materials.

– Secondary batteries are,

generally, more cost
effective over time than
primary batteries, since
the battery can be
recharged and reused.

Continuously Raising The Bar

Battery Construction

Continuously Raising The Bar

 Lead acid coupling

Positive PLATE = LEAD DIOXIDE (PbO2)

Negative PLATE = SPONGE LEAD (Pb)

ELECTROLYTE = DILUTE SULPHURIC

ACID (H2SO4)

Continuously Raising The Bar

 Cell basics

POSITIVE NEGATIVE
PLATE PLATE

+++ ---
+++ ---
ELECTROLYTE
+++ ---

ENERGY CONVERTER
CHEMICAL ELECTRICAL
When two different metals are put in a di-electric medium, a
(Voltage) is developed between the metals. The voltage
developed depends upon the type of metals and the
electrolyte/Solution used.
Continuously Raising The Bar
 Performance Governing Standards

• Japanese Industrial Standard (JIS)

 Capacity Test (C20 & C5)

• European Standard (DIN)  Charge Acceptance Test
 Reserve capacity Test
 Cold Cranking Capacity Test
• International Standard (IEC)  High Rate Discharge Test
Usually not
followed
 Charge Retention Test
 Vibration Test
• American Standard (SAE)  Water Loss Test
 Life Cycle Test

Continuously Raising The Bar

 Battery Nomenclature

38 B 20 R

widt
34 36 38 h

total
heigh
Performance Rating t
< 50, incremented
by 2
> 50 , incremented
by 5 length R-Type

L-Type
Continuously Raising The Bar
Layout & Terminal Identification

Continuously Raising The Bar

 Bar Code

No. of digits in Serial No. 14

Ex. 0 0 1 2 3 3 1 0 A 9 0 0 0 1
001-500 – Stands for Four wheeler ( 1st three digits)
001-100 – Stands for After market segment
101-200-Stands for OEM
501-999-Stands for Two wheeler
1,2,3-Stands for Plant code
1,2,3-Stands for Shift code
1,2,3 –Stands for line code
Date code-Actual 2 digit of date
Month code-(e.g…Jan=A/Feb=B/March=C and Dec=L)
Year Code-Print last digit of years eg.For 2006 is 6
Serial number-Re initialize to 0001 for every day at the beginning of I-Shift

Manufacturing code in 2010 batteries is O.

i.e. MFG code for a battery manufactured in JAN2010 will be A0

Continuously Raising The Bar

Working of Battery & Performance Parameters

How does a battery work

Chemical reactions

Performance parameters

Shelf Life

Battery Charging

Continuously Raising The Bar

 How does Battery Work?

Voltage is produced by a chemical reaction. Inside a

battery there are positive and negative lead plates that
sit in a liquid called electrolyte solution. Electrolyte
solution is a mixture of water and sulfuric acid.

When this solution interacts with the lead plates,

there's a chemical reaction. This chemical reaction
creates pressure that we call "voltage." The pressure
(voltage) pushes the current out of the battery's
negative terminal through the "load', the equipment
drawing the power. The current returns through the
positive terminal.

Continuously Raising The Bar

 Chemical reaction
Discharge

PbO2 + 2H2SO4 + Pb ChargePbSO + 2H2O + PbSO4

4
(+ve) Electrolyte (-ve)
(- (+ve) Electrolyte ((--ve)

At discharge, lead dioxide in positive plates and spongy lead in negative plates
react with sulphuric acid in the electrolyte and gradually transform into lead
sulphate and during this the sulphuric acid concentration decreases.

Conversely( During Charge ), when the battery is charged, the positive and
negative active materials which had been turned into lead sulphate gradually revert
to lead dioxide and spongy lead respectively thus releasing the sulphuric acid
absorbed in the active materials and during this the sulphuric acid concentration
increases.

When battery charging approaches its final stage, the charging current is consumed
solely for-electrolytic decomposition of later in the electrolyte resulting in generation
of oxygen gas from positive plates and hydrogen as from negative plates. The
generated gas will escape from the battery causing a decrease of the electrolyte,
thereby requires occasional water replenishment.

Continuously Raising The Bar

 Reactions at Anode & Cathode
During Discharge During charge

Oxygen Gas
releases from
+VE

Hydrogen Gas
releases from -
- VE

Continuously Raising The Bar

 Battery performance parameters
Amp-hours (AH)

Most common and appropriate way of battery rating

• Defined as the constant current a battery can be discharged at for 20 hours
before Voltage drops to 10.5V, (@ 27°C)
• For example, a 105AH battery will deliver 5.25A for 20hours
• Can be approximated by multiplying RC times 0.65

Reserve capacity (RC)

• Defined as the number of minutes a battery can deliver 25A before voltage
drops to 10.5V (@ 80°F) –The average Load (amps) taken by the head
lamps & tail lamps is approx 25 AMPS
• Can be approximated by dividing AH by 0.65

Cold cranking amps (CCA)

• Defined as the number of amps a battery can deliver for 30
seconds before voltage drops to 7.2V @ -18°C, only meaningful for
engine starting batteries
Continuously Raising The Bar
 Battery performance parameters
CAPACITY
It is the product of the constant current drawn from the battery
and the time in hours taken for the voltage to drop to 10.50V.
Since most of the Automotive batteries are designed on C20
rating hence The capacity of a battery can be defined – Time
in hours taken to discharge a battery for 20 hours X
Discharge current. The constant current should be C/20
For e.g., for a 60Ah battery, a constant current of 60/20 =
3Amps is drawn and if it takes 20 hours for voltage to drop to
10.50V, then capacity is 3 X 20 = 60Ah

In other words, if the capacity of the battery is as per required

specs, then it should discharge for at least 20 hours before
dropping to 10.50V

Continuously Raising The Bar

Understanding RC & CCA relations…

Battery with high CCA and 100% reserve

capacity.
A high CCA battery can be compared to a large,
open tap that allows unrestricted flow

More cranking ability.

Battery with high CCA but low reserve

capacity.
The cranking on this battery is good but running
on auxiliary power will drain the battery quickly.

More cranking ability but low back up.

Battery with low CCA but high reserve capacity.

The low CCA of this battery provides poor cranking
although the reserve capacity is high.

Low Cranking ability but high back up

Continuously Raising The Bar

 Shelf Life

• TGY Batteries made of Special plates

formation, High Specific gravity
ensuring the shelf life more than
90days unlike others.

• Drop in voltage of TGY batteries are

66% lesser than the competition
ensures good state of charge even
after 90days.

0 10 20 30 40 50 60 70 80 90
In Sb- Sb batteries,Drop of voltage / day is .033 volt (90 days = 2.97 volts)
Hence after 90 days, voltage drops to 12.4-2.97 = 9.43 volts i.e. discharged
In Ca- Ca Drop of voltage / day is .01 volt (90 days = 0.9 volts)
Hence ca-ca voltage drops to 12.7-0.9=11.6 volts

Continuously Raising The Bar

 Battery Charging

Constant voltage and constant current charging

• The modern day batteries are supplied in pre charged condition and fitted
on the vehicles. The IFC of these batteries are done before shipment.

• Charging can be of two types

CV - constant voltage charging
CC - constant current charging
CCCV- Constant Current Constant Voltage

• On vehicles the method of charging is CV but bench charging is mostly CC

Continuously Raising The Bar

 Charging of Battery

Parallel Connection – Volt Remains Series Connection – Volt will

same capacity is multiplied multiplied capacity remains same

Continuously Raising The Bar

 Types of Charging

Batteries can be connected series, parallel or a combination

Batteries connected in series produce a voltage equal to the sum

of battery voltages - AH and RC do not increase

Batteries connected in parallel produce AH and RC roughly

equal to the sum of AH and RC of both the batteries - battery
bank voltage does not increase
Color for + ve

Continuously Raising The Bar

 Installation &Maintenance of Battery

Installation Procedure

Dos & Don'ts

Factors Affecting Battery Life

Continuously Raising The Bar

 Battery Installation…

Never hammer cable terminals

onto battery posts. The lid,
internal post connections or
post lid insert connections
could be severely damaged.

Step – 1 Turn OFF Engine

Step – 2 Remove Earth Cable then +ve Cable

Step –3 Loosen Clamping and Dismantle

Battery
Any time a new battery is
fitted the electrical system
should be fully checked to
ensure starter, alternator
and voltage regulation are
operating correctly and that
there are no leaks to earth
Step – 4 Place New Battery Firmly Step – 5 Connect +Ve Cable then earth Cable

Continuously Raising The Bar

 Do’s

• Check the Sp. Gravity in each cell at least once in 60 days, and if the gravity is less than 1.250
(For Tractor, CV & Inverter – 1.230 ) and UNEVEN specific Gravity is observed put battery on
bench charge.

• If the level is low, Top up with distilled water only.

• Always keep the battery surface dry & dust free.

• Clean the battery TOP with a wet cloth dipped in a diluted washing soda solution to remove acid
and dirt.

• Clean the battery terminals with the help of a fine Copper wire brush or Terminal Cleaner to
remove corrosion and grease removal sprays to clean the battery terminals to remove corrosion.

• Apply Petroleum jelly or Vaseline on battery terminals and fixing clamps.

• Check for the tightness of fan belt, earth terminal, solenoid switch connection, battery cable
condition, cable connection with the terminals and starter motor, Alternator connection.

• Check for the alternator output voltage across the battery terminals.

• Make sure that the battery is firmly hold on the Cradle and tight the Hold on clamps properly-Do
not over tighten or keep it loose.

Continuously Raising The Bar

 Don'ts

• DONT'S

• Never check the battery by short circuiting of Terminals.

• Never disconnect battery terminals when engine is in “ON” position.

• Never wash the battery with pressure water.

• Never apply grease on battery terminals.

• Never hammer down battery terminals.

• Never remove electrolyte.

• Never add acid.

• Never use tap water/well water/stream water for topping up.

Continuously Raising The Bar
 Factors affecting battery life

• LEAVING IDLE
- Due to self discharge ,+Ve /-Ve gets converted in to PbSO4
( SULPHATION)

• NEGLECTING TOPPING UP, INCASE OF DRY OUT

- Exposed portion gets oxidized thus reduces the battery life
•
•IMPURE WATER ( TAP water, Well water, Minerals Water etc)
- Local Cell formation takes placed due to organic impurities (i.e.-Fe
,Mg etc) present in the TAP water due to which self discharge increases and chlorine
which is strong de colorant damages separators.

•OVERCHARGE
- Due to elctrolysis, water losses can damage the battery plates
permanently.
• UNDERCHARGE
- Can cause acid stratification.( Having different sp.gravity at different
levels in Electrolyte,like bottom, Middle & Top portions)
•
•HIGH SPECIFIC GRAVITY
- Damage to Positive plates due to heavy Corrosion.
Continuously Raising The Bar
 Factors affecting battery life

•WRONG FITMENT
- Fitment of undersize battery will result in to premature failure as
battery is prone to more electrical Loads more than prescribed load which will
result in running of battery under partial discharge condition.

•KEEPING BATTERY TOP WET/DIRTY

- Will lead to self discharge.

•TOPPING UP WITH H2SO4.

-Damage to Positive plates due to heavy Corrosion/Acid Stratification.

•IMPROPER INSTALLATION.
- Due to vibration active material shedding from +VE plate can take
place and loose fitment can also result in to pole / container damage.

Continuously Raising The Bar

 Battery Testing

Basics of Battery Testing

Three Step Battery Check

Checking SOC

SOC Vs Temp

Temperature Correction

Testing of DM water and Sulphuric Acid

Continuously Raising The Bar

 Battery Testing- Basics
VISUAL INSPECTION
CHECK - For Damage,
Appearnce, Poles condition, Use Calibirated
Do temp correction Corrosion, Vent Plugs Condition,
Electrolyte Level Hydrometer and
for accuracy in
Specific Gravity
Multimeter for
readings( Add or acuracy in reading
Deduct 0.005
Reading on every and keep the
CHECK
10Degree decrease
OCV - SPECIFIC GRAVITY -
or increase in temp.
CELL TO CELL VOLTAGE

IF :- SG is OK,
OCV is OK :::- IF:- One or two cells are
Pe rform HRD show ing Nil SG :- Check Cell
Test(Loa d of 1/2 of IF : - Specific to cell and if cell to cell in
the CCA or sele ct Gravity is Uneven :- NIL SG cell is also NIL and
the Nob on corre ct Equalise and other cells are OK :-
Batte ry type on Charge DEFECTIVE BATTERY
HRD Te ste r

Continuously Raising The Bar

 3-Step Battery Check

• Step 1 : Visual Inspection

• Check container, cover and terminal for damage

• Check & Clean corrosion if present A Wet & filthy top
• Check for electrolyte discoloration
surface will lead to
current leakage
• Step 2 : State Of Charge
from the battery
• Check SOC and SG with a Multi meter.
• Check Sp. Gravity readings of each cell. If any cell has got more than 40 points difference
than the other cells when the battery SOC is greater than 75% replace the battery
• Remove Surface Charge if any
• Equalize SG of all cells before putting battery on bench charge
• If SOC is less recharge the battery

• Step 3 : Load Test

• Apply Load of ½ the CCA rating of the battery for 15 seconds or select the HRD Tester nob
on the appropriate Load and test it.
• If Voltage reading is less than 9.8 volts replace the battery
• The load test is to be done only if the battery is in 100% SOC condition.

Continuously Raising The Bar

 Checking SOC of Battery

Specific gravity means exact weight of acid

with that of water
Rubber Ball

A hydrometer is used to measure the exact

Hydrometer weight of electrolyte with that of water
S
y
ri Strong electrolyte in a charged battery is
n
g heavier than weak electrolyte in a discharged
e battery
H
y
Diluted Sulfuric Acid
d
r Outer Tube (transparent)
o SOC VOLTAGE S.G
m
Sucking Bulb
e
t
e 100% 12.60-12.80 1.270-1.280
r
75% ~ 100% 12.40-12.60 1.230-1.240

50% ~ 75 % 12.20-12.40 1.190-1.200

Cell Voltage = Specific Gravity + 0.84 25%~ 50% 12.00-12.20 1.145-1.155

0% ~ 25% 11.70-12.00 1.100

Continuously Raising The Bar

 SOC VS Temp
Even a little Voltage means a lot
Only
12.80 OCV
0.7 volt
difference

12.20 OCV Full charge

½ charged

Continuously Raising The Bar

 Temperature Correction -Specific Gravity
Specific gravity varies with the temperature.

If the electrolyte temperature is substantially above 27OC add seven points (0.005) to the
observed specific gravity reading for every 10OC by which the actual temperature is
above 27OC.

Deduct Five points per 10OC where the observed reading is below 27OC to obtain the
temperature corrected reading at 27OC.

E.g, For observed gravity 1.240 at 35OC,

true gravity is

1.240 +(0.005/10 X 8) = 1.244 at 27OC.

Specific gravity should not be measured immediately after topping up a cell as the added
distilled water will not have diffused enough and will give false reading.

A charge for sixty minutes(1 Hour ) or more after topping up will mix the electrolyte
properly and allow accurate readings to be taken.

Continuously Raising The Bar

 How to check D.M water and Electrolyte Quality

Testing of Distilled water

• Check1: Take a distilled water in a clean glass. Immerse a “Series wire with a bulb” in to it and
pass a smaller current . If water is pure the bulb will not glow and if the water is impure the bulb
will glow.

• Check2:Take a sample of distilled water in a clean glass Add 2 to 3 crystals of a silver nitrate. If
chlorine is present ,water will turn “milky white” & if water does not change colour it means the
DM water is pure.

Testing of Sulphuric acid(H2SO4)

• 1.Put concentrate acid in a clean glass.

• Pure Automotive Battery Acid will be colour less.
• Industrial acid will have yellowish colour.
• 2. Add few drops of potassium permagnate in a distilled water in a clean glass and stir a few –
Stirring is not required drops of that solution and add to acid in the glass from a distance
• If acid is pure potassium solution will form a ring on top of the glass. If Potassium permagnate
dissolves in acid the ACID is impure.

Continuously Raising The Bar

 Field Failure Analysis

Types of Failure

Reason of Failure

Failure Analysis

Failure Symptoms, Reasons & Recommendations

Continuously Raising The Bar

 Typical Battery Failures

• Inherent Failure
– Ageing
– Corrosion
– Shrinkage
– Shedding
– Heat Seal Leakage
– Loose Connection/Internal Disconnection

• Induced Failure
– Sulphation
– Burst
– Discharge
– Over Charge
– Under Charge
– Long Storage
– Damage

Continuously Raising The Bar

 Field Failures
Reasons for failures

The reasons that most batteries fail prematurely are related to one or more of the
following:

• Improper charging

• Lack of water

• Installation

• Operational issues

Vehicle Battery

Imbalance loads Low State of Charge

Parasitic Drain Poor Charge Acceptance
Mechanical Problem

Note that the user has control over most of the conditions that lead to premature
failure.

Continuously Raising The Bar

 Field Failure analysis
DEFECT TYPE SYMTOMS REASONS RECOMMENDATION
Lead Run REPLACE

Field Abuse- metal Ingress REJECT

Separator missing REPLACE

1 or 2 cells Lump in the Plate REPLACE

Check Application-If OK-REPLACE
Dandrite shorts formation due to
but suggest cust to ge t the electrical
Undercharging
system checked/re ctifie d
Separator Puncture Check Application-If OK-Re place

OCV >13Volts, Electrolyte Level Low Overcharging REJECT

Physical Damage and topping up with Acid REJECT
OCV > 13 Volts , Dry
Overcharging REJECT
REJECT -Suggest e lectrical system
Grid Corrosion & Grid Growth
rectification
Under Charging -Dandrite Shorts
REJECT
Developed in all Cells
OCV <10Volts , All cells 1.100 or all cells Intercell Disconnection REPLACE
1.200
REPLACE but suggest cust to get the
Pole Disconnection -Pole melt from inside
electrical system checked/rectified
Under Charging -Dandrite Shorts
REJECT
Developed in all Cells
REPLACE but suggest cust to ge t
Pole Disconnection -Pole melt from inside the e lectrical system
checked/rectified
OCV <6Volts , Unequal gravity in all cells
Field Abuse- metal Ingress Reje ct
Check Application-If OK-REPLACE
Dandrite shorts formation due to
but suggest cust to ge t the electrical
Undercharging
system checked/re ctifie d
Lead Run REPLACE
INTERNAL SHORT O Voltage ( Due to lead run) REPLACE-Suggest electrical system
All cells Shorted at Bottom
rectification

Separator Puncture Check Application-If OK-REPLACE

Check Application-If OK-REPLACE
Dandrite shorts formation due to
but suggest cust to ge t the electrical
Undercharging
system checked/re ctifie d
Replace but suggest cust to get the
Open Circuit Voltage ≥12.0V Ingress of metals
electrical system checked/rectified

Lump in the Plate REPLACE

Poor Separator Quality REPLACE

Separator Puncture Check Application-If OK-REPLACE

Reje ct -Deep Discharge Batte ry -
Separator missing Suggest e lectrical system
rectification
High gravity in defective Cells
Separator Puncture Check Application-If OK-Re place

Crackes in Cos Bar Continuously Raising The Bar

Check Application-If OK-Re place
 Field Failure analysis

DEFECT TYPE SYMTOMS REASONS RECOMMENDATION

Blow hole ( Mfg defect ) REPLACE
Open Circuit Voltage <12.0V Jump start – Pole internal melt REPLACE
No weld (MFG defect) REPLACE

OCV fluctuation Refer - Loose Connection

Separator Missing(Mfg Defect) REPLACE
Nil gravity in defective Cells Improper weld at Inter cell weld(Mfg Defect) REPLACE
Reverse Assy.(MFG Defect) REPLACE
Poor Weld(MFG Defect) REPLACE
Blow hole ( Mfg defect ) REPLACE
OPEN CIRCUIT Loose connection between strap and
No response to crank plates
REPLACE

Refer - Loose Connection

Refer - Cell Short
REPLACE/REJECT -If Application-If
OK-Replace but suggest cust to get
Dandrite shorts formation-deep Discharge
the electrical system
checked/rectified
No gassing during bench Charging
Poor Weld (MFG Defect) REPLACE
Strap Cut (MFG Defect) REPLACE
Post Disconnection (MFG Defect/Abuse) REPLACE

Continuously Raising The Bar

 Field Failure analysis
DEFECT TYPE SYMTOMS REASONS RECOMMENDATION
REJECT-Suggest electrical system
Over Charging
rectification
Paste Shedding- (MFG Defect/Abuse) REPLACE
OCV, Gravity OK - fails on load
Improper weld at Inter cell weld- (MFG
REPLACE
Defect)
Blow hole ( Mfg defect ) REPLACE
LOOSE Improper weld at Inter cell weld - (MFG
REPLACE
Defect)
CONNECTION
Gravity ok But OCV fluctuats Blow hole ( Mfg defect ) REPLACE

Sulphated REJECT

Improper weld at Inter cell weld- (MFG

Check Application-If OK-REPLACE
No Voltage between cells -Cell to cell votage Defect)
check
Blow hole ( Mfg defect ) REPLACE

PHYSICAL Leakage of Electrolyte Pole Damage ( Blow hole- MFG Defect) )

REJECT
DAMAGE One or more dry cell Container Damage

Leakage from container/Bottom Container Damage REJECT

LEAKAGE
Leakage/spillage from joint of in between top
Poor heat sealing REPLACE
cover and container

Alternator defective ( Dry cells, if electrolyte

OVERCHARGED OCV, Gravity OK - fails on load is added gravity does not pick up)
REJECT

Continuously Raising The Bar

 Field Failure analysis
DEFECT TYPE SYMTOMS REASONS RECOMMENDATION
Prolonged storage -Deep
Chargers triping off during charging. Sulphation/Short/Plates hardening
Improper formation leading to stratification/
abnormal heating during bench charge plates hardening

Excessive loads - Advice Customer REPLACE :- Refer MFG Defect,

REJECT- Refer Abuse,OK- Advice
Earth Leakage Current Customer to get the electrical system
Open Circuit Voltage ≥12.0V rectified
Larger Capacity Battery

Undercharging -REFRE DISCHARGE

White Crystal sulfate forming in plate surface Deep Discharged

Check Application-If OK-REPLACE

Dandrite Shorts but suggest cust to get the electrical
Open Circuit Voltage ≥12.0V system checked/rectified
SULPHATION Reverse Assy. (MFG Defect) REPLACE
Check Application-If OK-REPLACE
Dandrite Shorts due to undercharging but suggest cust to get the electrical
Nil or Low Specific Gravity (Equal in all cells) system checked/rectified
Lead Run (MFG Defect/Abuse) REPLACE
Check Application-If OK-Replace but
Dandrite Shorts due to undercharging suggest cust to get the electrical
system checked/rectified
Excessive loads Advice Customer to Get it rectified

uneven specific gravity Low alternator o/p Advice Customer to Get it rectified

Earth Leakage Current Advice Customer to Get it rectified

Long storage Maintain FIFO

Excessive loads Advice Customer to Get it rectified

Continuously Raising The Bar
 Field Failure analysis

DEFECT TYPE SYMTOMS REASONS RECOMMENDATION

OVER CHARGING – Vent Plugs missing,

Electrolyte dry out – OCV >13 V OR OCV <10 Over charge (Vent plug missing, Dry ) REJECT :- However it is
V ,Growth of Positive plates over separators. recommended that based on
the actual field conditons if a
DURING BENCH CHARGING of battery, if the battery gets burst within 03
Overcharging and spark during bench
clamps are corroded this will lead to the months from the date of
charging
creation of spark and will result in to burst. commisioning and there is no
evidence of External spark
BURST JUMP START – Can be identified with pole and abuse the case may be
External short ( Pole Melt )
damage considered for warranty.Ideally
Due to oxidation in exposed portion of if the battery is found OK( OCV-
Electrolyte Level below min level in 1 or more Strap/plates cracks or short circuit will OK, Plates condition-Ok, HRD-
cells develop which can result in to burst due to OK,Midtronic Test-OK, Cell to
sparks.
cell Volts -OK) the reason of
Vent plugs are clogged due to Dirt/Use of bust is always external.
VENT PLUG CLOGGED– Blow air and confirm screw driver to openn and close the VP.

Continuously Raising The Bar

 Vital Information, you must know

List of Equipments

Refresh Charging

Process Flow Chart for Complaint Redressal

Application Chart

Salient Features of TGY Batteries

Continuously Raising The Bar

 EQUIPMENTS
S.No Type of Equipment Desc. Qty

1 Automotive Charger Branded -JP Power/Elak Etc 1

2 Motor Cycle Charger Branded -JP Power/Elak Etc 1

3 Automotive Load Tester (HRD Tester) Branded -JP Power/Elak Etc 1

4 Motor Cycle Load Tester (HRD Tester) Branded -JP Power/Elak Etc 1

5 Auto Hydrometer Thimson 2

6 MC Hydrometer Thimson 2

7 Medtronic Tester -Optional -PBT300 MIDTRONIC Inc. USA 1

8 Spanners -12 x 13 2

9 Spanners - 8 X 9 2

10 Spanners -10 X 11 2

11 Box Spanner -12 x 13 1

12 General Tools Box Spanner - 8 X 9 1

13 Screw Driver- Philip Head 2

14 Screw Driver- Straight Head 2

15 Nose Pliers 1

16 Cutting Pliers 1

17 Vent Plug Opener NA 1

18 Jumper Wires NA 1

19 Inverter 800VA-Branded 1

20 Inverter Load Board 400 Watts Load 1

21 Petroleum Jelly NA 50 Gram

22 Distilled Water (DM Water) NA 5 Ltrs

23 Diluted Sulphuric Acid Battery grade 5 Ltrs

24 Apron Acid Proof 1

25 Acid Proof Gloves Acid Proof 02 Sets

26 Wooden Mallet NA 1

Continuously Raising The Bar

 REFRESH CHARGING
Final Specific
PRODUCT Final OCV- REFRESH CHARGE
Battery Types Battery Models SELF LIFE Gravity -Fully
CATEGORY Fully Charged PROCEDURE
Charged

Titanium 34B20R,38B20R/L,46B24LS,DIN44,DIN60 90 Days 12.80+/-0.005 1.280+/-0.010

Platinum 34B20R,38B20R/L,55D26R 60 Days 12.80+/-0.005 1.280+/-0.010

PCUV
34B20R,38B20R/L,65D26R/L,75D31R,80D
Gold 60 Days 12.80+/-0.005 1.280+/-0.010
31R

28B20R,34B20R,38B20R/L,DIN44,DIN60,6 Check OCV and Specific

Silver 45 Days 12.80+/-0.005 1.280+/-0.010
5D26R/L,75D31R,80D31R Gravity :- Remove the
vent plugs and put the
batteries on bench
CV Platinum 105E41, 165G51 45 Days 12.50+/-0.005 1.250+/-0.010
charge for a minimum
of 4 Hours(Always
charge with slow
TRACTORS Platinum 75D31RT, 95E41LT 45 Days 12.50+/-0.005 1.250+/-0.010 amperes only)

THREE WHEELERS Silver 65D26R,65D26L 45 Days 12.80+/-0.005 1.280+/-0.010

135G51 45 Days 12.50+/-0.005 1.250+/-0.010

INVERTER Platinum

150G51 45 Days 12.50+/-0.005 1.220+/-0.010

Continuously Raising The Bar
Complaint Process Flow Chart

Make the Battery

Complaint
report(BCR)

Continuously Raising The Bar

Complaint Process Flow Chart

Continuously Raising The Bar

Continuously Raising The Bar
 TGY Batteries Salient Features
Cut-Section View
Flush type Cover design
with flame arrestor to ensure
10mm
Electrolyte Head room
spill proofing and protect
more than competition
external spark entry
ensuring complete
immersion of plates
thorough out its service
life, avoids explosion,
No topping up required
more than 1.00000Km

Glass Mat Separator

Intercell Connection protects plate from
through partitions vibration impact and
ensures good cranking. ensures free diffusion of
electrolytes

Ca
Ca--Ca grid of positive plate
helps good charge acceptance
and overcharge resistance,
longer shelf life. Specially formulated
negative plate ensures
good cycle life.

Continuously Raising The Bar

 Salient Features of TATA Batteries

• Longer self life-Calcium Calcium advantage(Technology Edge)

• Maintenance free product-No top up over 100,000 KMS.

• Instant Start and trouble free performance

• Manufactured in collaboration with Japan world leader in

batteries.

• A product form the House of .

Continuously Raising The Bar

 FAQs
Question / Myth Answers / Facts

Always apply VASLINE or Petroleum jelly on terminals never apply Grease-Grease will
Grease can be used at Terminals
lead to the insulation between Terminal and Poles due to high risk of corrosion

Top of battery should be done with Battery Grade DM water only. Never add acid in
I can top up my battery with Sulphuric acid battery. Adding Sulphuric acid will damage battery due to stratification and corrosion of
positive plates due to high SG.
Torn Battery Cables or Torn strands of battery cable can lead to the voltage drop and
Torn battery cable and pitted Battery terminal
pitted battery terminals will create sparks at poles which will lead to the pole
wont make any effect on my battery
damage/Melting problems.

If my battery is discharge, alternator will Alternator in a vehicle can charge the battery only if the same is 80% charge. One should
charge it hence i don't need to bench charge immediately put the battery on bench charge if battery is more than 80% discharge
the battery (OCV<12.40V) to avoid capacity loss due to sulphation.

Fitment of undersize battery wont affect the Always fit the correct size of battery. Fitment of under capacity battery will lead to
electrical system and battery life. premature failure.

Never use/Fit inverter battery for vehicular application. Inverter batteries are designed
Inverter battery can also be used for Vehicular for stand by application where battery is design to discharge with certain amount of
(Truck) application current for longer duration where as in vehicular application batteries are designed to
provide Burst of heavy amount of current for fraction of seconds during engine cranking.

Never short circuit battery terminals as short circuiting will lead to flow of heavy current
I can check/Test battery by short circuiting of
across the battery terminals and can result in to short circuit of plates, Capacity loss or
both the poles
even burst.

I can fit extra load on my car and it wont effect If Load on your car exceeds the total output rating of the alternator, the battery will get
the battery life. discharge and it will shorten the life of battery. Continuously Raising The Bar
 FAQs

Question / Myth Answers / Facts

What happen if we fix battery in the

vehicle with reverse cables while If battery is connected in reverse this may cause damage to the expensive
fitment and start the vehicle. electronic parts of an automobiles. And damage the Alternator

The warranty on any battery is always based on the expected minimum life of a
why all the batteries co. giving reduced battery in terms of charge & discharge cycle.In commercial vehicle the no of
warranty for commercial vehicle. charge and discharge cycles are more in the same span of life period as
compared to the vehicles of personal use. Beside above the running pattern of
a vehicle is also effects the battery life.
TAP Water contains mineral impurities and chlorine which reduces battery
life.The minerals available in TAP Water e.g-Magnesium, Iron, etc will makes
what happen if we put tap water in the small -2 cells inside the battery and the chemical reaction which took places in
vehicle. between those bridges will discharge the battery even it is not in used.
Chlorine is a strong de colorant this will have adverse effect on separators
which will lead to the short circuiting of cells and result in to premature failures
of the battery.

what happen when we jump start the

The heavy amount of current which passes through the cells of a discharge
vehicle with not fully charged battery.
battery during JUMP START will damage the battery.

Continuously Raising The Bar

 TGY After market service policy
SALIENT FEATURES & COMPLIANCE
Infrastructure Requirement for Channel
Channel partners should have all required tools and testers beside dedicated Service manpower and service center
partners
Please make sure that once the battery is sold,it is mandatory to r egister the warranty card in our system (SAP) within 03 months
Warranty Cards Registration from the date of sale (Date of sale to end user)

Warranty adjudication is to be done at channel partners service center only. In case of doubt full cases or if the report is not
Warranty Adjudication
convincing the battery may be called at CFA also for further charging and testing .
At the time of warranty adjudication channel partner will provide the orginal warranty card of defective battery for varification
.Photocopy of orginal warranty card is require along with the original warranty card of new battery to process the claim under
Warranty documentation
FOC warranty and In acse of pro rata claim Orginal warranty card along with Registration portion of replaced card will be require
for processing of claim. The pri condition of warranty is that the battery should be registered in SAP .
Channel partners have to fill up the Battery complaint report at the time of recieving of battery at service center.This form is to
Battery Complaint Report( w.e.f -
be acknowledged by the customer.Complate Test report is to be filled by the franchisee and the documents are to be kept ready
10.05.2010 ) before the visti date of TGY service engineer.
Channel partners who have got full fledge service center with all required equipments and dedicated service manpower can only
Warranty adjudication authority replace a battery if it complaince to the service polciy . Service engineer will be visting channel partners on a fixed visit cycle and
the frequesncy of visit is to be decided on the basis of complaint volcumes.

Warranty on a battery which is Pre In case a battery is pre registered in SAP but the orginal card is lost the claim shall be hounoured if the
registered in SAP(Tiemly difference between the date of sale and date of manufacturing of battery is not more that 06 Months.Channel
registration) but original card is not partner have to provide the customers contact No at the time of warranty adjudication and This type of cases
available will be monitored by the Head Service regulary.

Warranty on a battery wherein

No warranty would be hounoured if the battery is UNREGISTERED and ORGINAL warranty card is also not
warranty card is not available and available.
battery is also not pre registered.

All the complaint has to be registered in customer care preferably through mail. Customer care will provide a
CRN no by return mail within 06 hours . If the battery is registered before the last date of warranty the same
Warranty on Border Line case shall be considered under warranty.If the complaint is not registered in Customer care the battery shall not be
considered for warranty.

Channel partners have to send warranty failure batteries to CFA on " PAID and DOOR DELIVERY " basis only. We also have pick and
Transportation of Failed batteries
delivery arrangments at base towns(CFA towns)

Batteries which has been discontinued by the company or if the stock of any particular model is not available for more than 15
Replacemnet of Discontinued Models days, the same shall be replaced by the alternative models. The replacement battery will carry the same warranty of orginal
battery .

If any battery is pending at CFA due to non availability of stock for more than 02 months , the same shall be settled through credit
Credit Not against pending battery Note. The pre condition is remain same that the battery should not be available for sales also during that stipulated 02 Months
period . In case of Discontinued models the claim is to be settled through alternative models only not through the Credit Notes.

Service Reibursement(Applicable on CFA Location Rs75/-

Recharged and return cases and Non CFA locations Rs90/-
FOC/Prorata Replacement) Metros (Mumbai, Delhi,Chennai and Kolkata) Rs.100/-

CP needs to get the CRN from Call center through Mail or Calling at 09213100000
Reibursment Criteria
Monthly reimbursement based on call centers data (through Trade discount or CN) Continuously Raising The Bar
Continuously Raising The Bar