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AS 4086.2—1997 

Licensed to ms kerrie Firth on 30 June 2010. 1 user personal user licence only. Storage, distribution or use on network prohibited (10127544). 

Australian Standard ® 

Secondary batteries for use with 

stand-alone power systems 

Part 2: Installation and maintenance

This Australian Standard was prepared by Committee EL/5, Secondary Batteries. It 

was approved on behalf of the Council of Standards Australia on 21 April 1997 and 

published on 5 October 1997. 


The following interests are represented on Committee EL/5: 

Australian Automobile Association 

Australian Automotive Aftermarket Association 

Australian Chamber of Commerce and Industry 

Australian Electrical and Electronic Manufacturers Association 

Australian Lead Development Association 

Electrical Development Association of New Zealand 

Electricity Supply Association of Australia 

Federal Chamber of Automotive Industries 

Telstra Corporation 

Additional interests participating in preparation of Standard: 

Solar Energy Industries Association of Australia 

Review of Australian Standards. To keep abreast of progress in industry, Australian Standards are subject 

to periodic review and are kept up to date by the issue of amendments or new editions as necessary. It is 

important therefore that Standards users ensure that they are in possession of the latest edition, and any 

amendments thereto. 

Full details of all Australian Standards and related publications will be found in the Standards Australia 

Catalogue of Publications; this information is supplemented each month by the magazine ‘The Australian 

Standard’, which subscribing members receive, and which gives details of new publications, new editi ons 

and amendments, and of withdrawn Standards. 

Suggestions for improvements to Australian Standards, addressed to the head office of Standards Australia, 

are welcomed. Notification of any inaccuracy or ambiguity found in an Australian Standard should be made 

without delay in order that the matter may be investigated and appropriate action taken. 

This Standard was issued in draft form for comment as DR 93342.

AS 4086.2—1997 


Australian Standard ® 

Secondary batteries for use with 

stand-alone power systems 

Part 2: Installation and maintenance 

First published as AS 4086.2— 1997. 

PUBLISHED BY STANDARDS AUSTRALIA 

(STANDARDS ASSOCIATION OF AUSTRALIA) 

1 THE CRESCENT, HOMEBUSH, NSW 2140 

ISBN 0 7337 1221 5

AS 4086.2 — 1997 2 

PREFACE 


This Standard was prepared by the Joint Standards Australia/Standards New Zealand 

Committee EL/5, Secondary Batteries. This Standard is the result of a consensus among 

Australian and New Zealand representatives on the Joint Committee to produce it as an 

Australian Standard. 

It is the second part of a two-part Standard on stand-alone batteries. The two parts are as 

follows: 

(a) AS 4086.1, Secondary batteries for use with stand-alone power systems, 

Part 1: General requirements. 

(b) This Standard. 

This Standard was prepared in response to requests from battery manufacturers and 

installers for a standard which specifically covers the installation requirements of standalone 

batteries. 

The terms ‘normative’ and ‘informative’ have been used in this Standard to define the 

application of the appendix to which they apply. A ‘normative’ appendix is an integral 

part of a Standard, whereas an ‘informative’ appendix is only for information and 

guidance. 

© Copyright STANDARDS AUSTRALIA 

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exclusively in-house by purchasers of the Standard without payment of a royalty or advice to Standards Australia. 

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payment provided such programs are used exclusively in-house by the creators of the programs. 

Care should be taken to ensure that material used is from the current edition of the Standard and that it is updated whenever the 

Standard is amended or revised. The number and date of the Standard should therefore be clearly identified. 

The use of material in print form or in computer software programs to be used commercially, with or without payment, or in 

commercial contracts is subject to the payment of a royalty. This policy may be varied by Standards Australia at any time.

3 AS 4086.2 — 1997 


CONTENTS 

Page 

SECTION 1 SCOPE AND GENERAL 

1.1 SCOPE ................................................. 5 

1.2 REFERENCEDDOCUMENTS ................................ 5 

1.3 DEFINITIONS............................................ 6 

SECTION 2 BATTERY ACCOMMODATION AND ARRANGEMENT 

2.1 GENERAL .............................................. 9 

2.2 CONNECTION BETWEEN BATTERY AND DIRECT CURRENT 

SWITCHBOARD .......................................... 9 

2.3 OVERCURRENTPROTECTION............................... 9 

2.4 THERMALRUNAWAY..................................... 10 

2.5 ALARMS ............................................... 10 

2.6 BATTERYENCLOSURE .................................... 10 

2.7 VENTILATION........................................... 11 

2.8 SAFETYSIGNS .......................................... 13 

SECTION 3 INSPECTION AND MAINTENANCE 

3.1 INSPECTION ............................................ 14 

3.2 MAINTENANCE.......................................... 14 

3.3 EARTHFAULTLOCATION ................................. 15 

SECTION 4 INSTALLATION AND COMMISSIONING 

4.1 UNPACKING ............................................ 16 

4.2 STORAGE .............................................. 16 

4.3 MOUNTINGANDCONNECTION ............................. 16 

4.4 COMMISSIONING ........................................ 17 

SECTION 5 SAFETY 

5.1 GENERAL .............................................. 18 

5.2 HANDLING, MIXING AND STORING OF ELECTROLYTE . . . . . . . . . . 18 

5.3 PROTECTIVEEQUIPMENT ................................. 18 

5.4 ELECTROLYTEBURNS .................................... 18 

5.5 WATERSUPPLY ......................................... 19 

5.6 PRECAUTIONS........................................... 19 

5.7 FIREFIGHTINGEQUIPMENT ................................ 20 

APPENDICES 

A DESIGN CONSIDERATIONS FOR BATTERY INSTALLATIONS . . . . . . . . 21 

B SAFETYSIGNS............................................ 24 

C INITIAL CHARGING AND COMMISSIONING OF VENTED 

LEAD-ACIDBATTERIES..................................... 26 

D INITIAL CHARGING AND COMMISSIONING OF VENTED 

NICKEL-CADMIUMALKALINEBATTERIES...................... 28


Page 


E INITIAL CHARGING AND COMMISSIONING OF VALVE-REGULATED 

NICKEL-CADMIUMBATTERIES ............................... 30 

F INITIAL CHARGING AND COMMISSIONING OF VALVE-REGULATED 

LEAD-ACIDBATTERIES..................................... 31 

G TYPICAL DIRECT CURRENT SYSTEM EARTHING . . . . . . . . . . . . . . . . . 32 

H SHORT-CIRCUITPERFORMANCEOFCABLES .................... 33 

I PERFORMANCETEST....................................... 38


STANDARDS AUSTRALIA 

Australian Standard 

Secondary batteries for use with stand-alone power systems 


Part 2: Installation and maintenance 

SECTION 1 SCOPE AND GENERAL 

1.1 SCOPE This Standard sets out recommended practices for the installation, 

maintenance, testing and replacement of secondary batteries, having nominal voltages not 

exceeding 115 V d.c., for use with stand-alone systems. 

Stand-alone systems are systems that are not connected to the power distribution systems 

of an electricity supply authority. Stand-alone systems are supplied with power from one 

of a number of sources: a photovoltaic array, a wind generator, a water generator, or a 

diesel generator. 

This Standard applies to the installation of all types of batteries including lead-acid and 

nickel-cadmium and covers both vented and valve-regulated cells. 

NOTE: AS 3011.1 and AS 3011.2 cover requirements for batteries having nominal voltages 

exceeding 115 V d.c. 

1.2 REFERENCED DOCUMENTS The following documents are referred to in this 

Standard: 

AS 

1006 Solid-stem general purpose thermometers 

1319 Safety signs for the occupational environment 

2184 Low voltage switchgear and controlgear— Moulded-case circuit-breakers for 

rated voltages up to and including 600 V a.c. and 250 V d.c. 

2444 Portable fire extinguishers and fire blankets—Selection and location 

2562 Hydrometers— Portable syringe-type for lead-acid batteries 

2668 Water for use in secondary batteries 

2669 Sulphuric acid for use in lead-acid batteries 

2676 Guide to the installation, maintenance, testing and replacement of secondary 

batteries in buildings 

2676.1 Part 1: Vented cells 

2676.2 Part 2: Sealed cells 

3000 Electrical installations— Buildings structures and premises (known as the SAA 

Wiring Rules) 

3011 Electrical installations— Secondary batteries installed in buildings 

3011.1 Part 1: Vented cells 

3011.2 Part 2: Sealed cells 

3111 Approval and test specification—Miniature overcurrent circuit-breakers 

3439 Low-voltage switchgear and controlgear assemblies 

3439.1 Part 1: Type-tested and partially type-tested assemblies 

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AS 

3947 Low-voltage switchgear and controlgear 

3947.3 Part 3: Switches, disconnectors, switch-disconnectors and fuse-combination units 

Other documents 

The Australian code for the transport of dangerous goods by road and rail. 


1.3 DEFINITIONS For the purpose of this Standard, the definitions below apply. 

1.3.1 Accessories —those items supplied with a battery to facilitate the continued 

operation of the battery. 

NOTE: Such accessories include distilled water in containers, connectors, connecting bolts and 

nuts, and hydrometers. 

1.3.2 Authorized person — the person in charge of the premises, or other person 

appointed or selected by the person in charge of the premises, to perform certain duties 

associated with the battery installation on the premises. 

NOTE: In some states, work on low and medium voltage equipment may be undertaken by 

licensed personnel only. 

1.3.3 Battery — a unit consisting of one or more cells connected in a series, parallel or 

series-parallel arrangement, to supply the voltage and current requirements of a connected 

load. 

1.3.4 Battery enclosure— an enclosure containing batteries that is suitable for use in an 

area other than a battery room or an area restricted to authorized personnel. 

1.3.5 Battery room— a room specifically intended for the installation of batteries. 

1.3.6 Boost voltage —a controlled overvoltage, above float voltage, to provide a rapid 

partial recharge of a battery. 

1.3.7 Capacity (C)—the quantity of electricity which a fully charged battery can deliver 

under specified conditions. 

NOTE: Capacity is measured in ampere hours (A.h). 

The capacity of a cell or battery is denoted by the symbol ‘C’. As the capacity varies with 

rate of discharge, the symbol ‘C’ is followed by a numerical suffix giving the rate of 

discharge. Thus, C 120 is the capacity in ampere hours at the 120 h rate of discharge. The 

specified temperature is usually 25°C. The final voltage depends on battery type and 

conditions of service. 

Capacity may be specified as follows: 

(a) Actual capacity — the quantity of electricity in ampere hours that can be drawn from 

a cell or battery for a specific set of operating conditions including discharge rate, 

temperature, initial state of charge, age, and final voltage. 

(b) Rated capacity — the quantity of electricity in ampere hours, declared by the 

manufacturer, which a battery can deliver after a full charge under specified 

conditions. 

NOTE: The specified conditions are rate of discharge, final voltage and temperature. 

1.3.8 Capacity test—the discharge of a battery to a designated terminal voltage. 

1.3.9 Cell—an assembly of electrodes and electrolyte which constitute the basic unit of 

a battery. 

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1.3.10 Charge/discharge rate —the current at which a battery is charged or discharged. 

This can be expressed in amperes or as a multiple of the rated capacity of the battery (see 

Clause 1.3.7). For example, if a battery is rated at 240 A.h at the 120 h rate of discharge 

and is being discharged at a current of 2 A, its discharge rate can be expressed as 

0.0083C 120 . 

1.3.11 Charging —an operation during which a battery receives electric energy, which is 

converted to chemical energy, from an external circuit. The quantity of electric energy is 

known as the charge, and is usually measured in ampere hours. 

1.3.12 Constant current charge —a charge during which the current is maintained at a 

constant value. 

1.3.13 Constant voltage charge —a charge during which the voltage across the battery 

terminals is maintained at a constant value. 

1.3.14 Container—a container for the plate pack and electrolyte of a cell constructed of 

a material impervious to attack by the electrolyte. 

1.3.15 Discharging —an operation during which a battery delivers current to an external 

circuit by the conversion of chemical energy to electric energy. 

1.3.16 Duty cycle — the specified output of voltage or current to be achieved by the 

battery for a given period followed by a charge current to restore the battery charge to an 

acceptable level. 

1.3.17 Electrolyte —a liquid or solid substance containing mobile ions which will render 

the substance ionically conductive: for example, sulphuric acid (H 2 SO 4 ) in lead-acid 

batteries and potassium hydroxide (KOH) in nickel-cadmium batteries. 

1.3.18 Electrolyte density — the density of the electrolyte measured in kilograms per 

cubic metre at a specific temperature (the density of pure water = 1000 kg/m 3 at 4°C). 

NOTE: The density of the electrolyte was formerly indicated by its specific gravity. Specific 

gravity is the ratio of the density of the electrolyte to the density of pure water. 

electrolyte density (in kilograms per cubic metre) 

S.G. 

1000 

1.3.19 Equalizing charge — an extended charge to ensure complete charging of all the 

cells in a battery. 

1.3.20 Extra-low voltage —not exceeding 115 V d.c. 

1.3.21 Final voltage (cutoff voltage, end voltage) —the prescribed voltage at which a 

discharge is considered finished. 

1.3.22 Float voltage —the voltage applied by the charging source to a battery in normal 

operation i.e. not in boost or equalizing mode. 

1.3.23 Gassing— the formation of gas produced by electrolysis. 

1.3.24 Inter-cell and inter-row connections — those connections made between rows of 

cells. 

1.3.25 May—indicates the existence of an option. 

1.3.26 Monobloc battery— a secondary battery in which two or more cells are fitted in 

a multi-compartment container. 

1.3.27 Nominal voltage —a stated value of voltage used to identify a type of cell. For 

the purpose of this Standard, the nominal voltage of a lead-acid cell is 2 V and that of a 

nickel-cadmium cell is 1.2 V. 

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1.3.28 Output conductors — conductors from a battery to its load. Conductors 

connecting strings of cells in series are not output conductors. 

1.3.29 Performance test— a test of the capacity carried out in order to compare the 

capacity of a battery with its rated value, or a previously measured value. 

1.3.30 Pilot cell— a selected cell of a battery which is considered to be representative of 

the average state of the battery or part of the battery. 

1.3.31 Prospective fault current—the highest level of fault current that can occur at a 

point in a circuit. This is the fault current that can flow in the event of a zero impedance 

short-circuit and if no protective devices operate. 

1.3.32 Safety vent —a special design of vent plug which provides protection against 

internal explosion when a cell or battery is exposed to a naked flame or external spark. 

1.3.33 Service life —the period of the useful life of a battery under specified conditions. 

1.3.34 Service test— a special test of the ability of a battery to satisfy the design 

requirements (e.g. battery duty cycle) of the d.c. system. 

1.3.35 Shall —indicates that a statement is mandatory. 

1.3.36 Should —indicates a recommendation. 

1.3.37 Shroud— an insulated cover to protect the terminals and inter-cell connectors 

from inadvertent contact by personnel, and accidental short-circuiting. 

1.3.38 Terminal post —a part provided for the connection of a cell or a battery to 

external conductors. 

1.3.39 Tiered stand—a stand on which rows of containers are placed above containers 

of the same or another battery. 

1.3.40 Transit plug—a special plug fitted to the cells for transit. 

1.3.41 Vent plug—a part closing the filling hole which is also employed to permit the 

escape of gas. 

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SECTION 2 BATTERY ACCOMMODATION 

AND ARRANGEMENT 


2.1 GENERAL The major considerations in the design of a battery installation are — 

(a) the size and type of battery; and 

(b) the ratings and types of switchgear and conductors. 

The size and type of battery depend upon the requirements and function of the d.c. system 

of which the battery is a part. 

The major considerations in switchgear and conductor selection are as follows: 

(i) Rated operational voltage. 

(ii) Rated continuous current of switchgear. 

(iii) Fault current levels. 

(iv) Rated making and breaking current of switchgear. 

NOTE: Appendix A provides guidance on a number of matters that should be considered when 

designing a stand-alone battery system. 

2.2 CONNECTION BETWEEN BATTERY AND DIRECT CURRENT SWITCHBOARD 

2.2.1 General Any cable, busway or busbar forming the connection between a battery 

terminal and a d.c. distribution board should be rated to withstand the prospective shortcircuit 

current which the battery is able to deliver for a period of at least 1 s (see 

Appendix H). 

2.2.2 Cables Cables should be effectively clamped and sufficient support should be 

provided throughout the length of cables to minimize sag, and prevent undue strain from 

being imposed on the cables or on battery terminals or other parts of the installation. 

Cables shall not be bent through a radius less than the minimum bending radius specified 

by the cable manufacturer. 

2.2.3 Inter-cell and battery terminal connections Electrical connections between 

cables on separate levels or stands should be made so as to minimize mechanical strain on 

the battery posts. 

Inter-cell connector shrouds are recommended to prevent accidental short-circuits on the 

battery. The shrouds should have access holes for meter probes. 

Inter-cell and battery terminal connections should be constructed of materials either 

intrinsically resistant to corrosion or suitably protected by surface finish against corrosion. 

The joining of materials that are incompatible in a corrosive atmosphere should be 

avoided. 

2.3 OVERCURRENT PROTECTION The output conductors of a battery shall be 

protected against overcurrent by a fuse or circuit-breaker in at least one output conductor. 

A battery which does not have either output conductor connected to earth shall be 

provided with a fuse or circuit-breaker in each output conductor. 

Rewirable fuses shall not be used for this purpose because they can initiate fires and 

explosions. 

Protective devices should be selected from the following: 

(a) Fuses, in accordance with AS 3947.3. 

(b) Combination fuse-switch units incorporating HRC fuses, in accordance with 

AS 3947.3. 

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(c) Miniature circuit-breakers (MCBs), in accordance with AS 3111 or moulded case 

circuit-breakers (MCCBs), in accordance with AS 2184. 

MCBs and some MCCBs have limited short-circuit current ratings and may require 

to be backed up by HRC fuses. 

The installation should be arranged so that it is possible to completely isolate the battery. 


2.4 THERMAL RUNAWAY A badly designed installation having poor cooling 

ventilation, no temperature correction or no voltage limitation in the charging system can 

result in thermal runaway of valve-regulated cells. This can result in fires and possible 

loss of the battery. The battery supplier should be consulted as to the appropriate 

installation design. 

2.5 ALARMS It may be desirable to provide alarms indicating overcurrent or 

overvoltage conditions, or alternatively, the battery charger may automatically shutdown if 

overcurrent or overvoltage conditions occur. 

It is desirable to receive an early warning of high or low battery voltage for the following 

reasons: 

(a) An indication of low battery voltage warns against— 

(i) discharging the battery to an extent that is unsuitable for normal operation of 

the load; and 

(ii) maintaining the battery in a discharged condition. 

Either of the above will shorten the life of cells, particularly cells of lead-acid 

batteries. 

(b) An indication of high battery voltage warns against overcharging the battery and 

reduces the risk of damage to battery-charging equipment. 

When a battery is receiving a charge (other than a float charge), suitable detectors should 

monitor the battery voltage so that when the battery reaches full charge either the charge 

rate is reduced automatically, or an alarm is initiated. 

When a battery is receiving a float charge, suitable detectors should monitor the battery 

voltage and initiate an alarm if the voltage exceeds or falls below the normal operating 

voltage limits of the rectifier or generator which is permanently connected in parallel with 

the battery. 

Detection devices should incorporate a time delay to avoid spurious operation of alarms 

by transient voltages. 

2.6 BATTERY ENCLOSURE 

2.6.1 General Batteries shall be protected by means of a suitable enclosure. This may 

take the form of a box, a room or steel wire mesh. It should be clean, dry, adequately 

ventilated, and provide and maintain protection against detrimental environmental 

conditions. 

2.6.2 Layout and location Batteries shall be located in accordance with the 

manufacturer’s recommendations. The following additional considerations apply to the 

battery location: 

(a) Arc-producing devices shall not be located in areas where hydrogen concentrations 

can become significant, e.g. directly above battery cells. 

(b) The design of the battery installation should be such that localized heat sources such 

as sunlight, generators, steam pipes, walls exposed to direct sunlight and space 

heaters are avoided. 

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(c) 

(d) 

Extreme ambient temperatures should be avoided because low temperatures decrease 

battery capacity and prolonged high temperatures shorten battery life. 

The enclosure location shall provide adequate structural support and be as free of 

vibration as possible. 

NOTE: AS 2676.1 and AS 2676.2 provide guidance on the construction of battery 

enclosures. 

(e) The battery location should preclude contamination of water supplies and damage to 

equipment in the event of electrolyte spillage. 

(f) A battery should not be located near combustible material or near metal objects 

capable of falling across battery terminals and causing a short-circuit. 

2.6.3 Mechanical considerations The following matters should be taken into 

consideration in the design of the enclosure: 

(a) The size of the enclosure should allow for sufficient clearance around the battery to 

provide access for installation and maintenance. Consideration should be given to 

the space required for safety equipment and handling equipment. 

(b) The supporting surface of the enclosure shall have adequate structural strength to 

support the battery weight and its support structure. 

(c) The enclosure should be resistant to the effects of electrolyte, either by selection of 

materials used or by appropriate coatings. Provision should be made for the 

containment for any spilled electrolyte. 

(d) Any enclosure doors should allow unobstructed exit. 

(e) The enclosure design should include appropriate means to prevent access by persons 

not aware of the hazards of battery banks. 

2.7 VENTILATION 

2.7.1 General All battery installations, for both vented and valve-regulated batteries, 

should be supplied with either natural or forced ventilation. 

All secondary cells generate hydrogen and oxygen gases during charging. The major 

release of hydrogen gas occurs after a cell has achieved 95% of charge, or during any 

boost charging or overcharging of the battery. 

The chemistry of a valve-regulated battery operates on an internal oxygen-recombination 

cycle which is arranged to suppress hydrogen gas evolution. Under normal operating 

conditions, hydrogen gas evolution and venting in valve-regulated cells is much lower 

than the hydrogen gas released by conventional vented (flooded) cells. The hydrogen 

suppression efficiency in valve-regulated batteries varies with cell technology, but 

typically exceeds 80% for gel cells and 90% for absorbent glass mat cells. 

However, under conditions of overcharge or electrical abuse, significant amounts of 

hydrogen gas can be generated and emitted from valve-regulated cells. Further, the 

thermal management of valve-regulated cells under charge is more critical than for vented 

cells, and generally the valve-regulated cell will be irreversibly damaged when subjected 

to sustained electrical abuse, therefore, the manufacturer’s recommended charging regime 

for valve-regulated batteries should be observed. 

2.7.2 Rate of hydrogen evolution The average hydrogen concentration by volume in a 

battery enclosure shall be maintained below 2%. 

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2.7.3 Exhaust ventilation rate The minimum exhaust ventilation rate required to 

maintain hydrogen concentration below 2% is calculated by the following equation: 


q v = 0.006nI ...2.7.3 

where 

q v 

= the minimum exhaust ventilation rate, in litres per second 

n = the number of battery cells 

I = the charging rate, in amperes (see Clause 2.7.4) 

If there is more than one battery in an enclosure, then the total exhaust ventilation rate is 

the sum of the rate of all the batteries. 

2.7.4 Charging rate 

2.7.4.1 Vented cells The charging rate for vented cells (I) in Equation 2.7.3 is the 

maximum design rating of the charging source (e.g. a solar array, a diesel generator or a 

battery charger) or the rating of the output fuse or circuit-breaker of the charging source. 

2.7.4.2 Valve-regulated cells The charging rate for valve-regulated cells (I) in 

Equation 2.7.3 is determined for two conditions as follows: 

(a) Condition I If the charger does not have an automatic overvoltage cutoff, the 

charging current is the maximum output rating of the charger or the rating of the 

output fuse or circuit-breaker of the charger. 

(b) Condition II If the charger has an automatic overvoltage cutoff set at the battery 

manufacturer’s recommended level the charging rate is— 

(i) 0.5 A per 100 A.h at the 3 h rate of discharge of battery capacity for 

lead-acid batteries; and 

(ii) 1.5 A per 100 A.h at the 3 h rate of discharge of battery capacity for 

nickel-cadmium batteries. 

NOTE: These charging rates are based on a float voltage of 2.27 V per cell for lead-acid 

batteries and 1.45 V per cell for nickel-cadmium batteries and have been selected to provide a 

safe level of ventilation for all types of battery construction. 

2.7.5 Method of ventilation 

2.7.5.1 General Where possible natural ventilation should be used for battery 

enclosures because of the fault potential of mechanical ventilation. 

2.7.5.2 Natural ventilation If natural ventilation is used, the minimum size of inlet and 

outlet apertures is determined from the following equation: 

A = 100q v 

...2.7.5.2 

where 

A = the minimum area of the apertures, in square centimetres 

q v = the minimum exhaust ventilation rate, in litres per second (see Clause 2.7.3) 

With natural ventilation, an air velocity of at least 0.1 m/s is assumed to flow through the 

apertures. 

2.7.5.3 Mechanical ventilation If mechanical ventilation is used, the minimum flow 

rate is determined by Equation 2.7.3. 

2.7.5.4 Arrangement of ventilation The following recommendations apply to the 

arrangement and layout of the ventilation system: 

(a) Exhaust air should not pass over other electrical equipment. 

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(b) 

(c) 

(d) 

(e) 

(f) 

(g) 

(h) 

Battery enclosures should be provided with ventilation by means of holes, grilles or 

vents so that air sweeps across the battery. To avoid stratification of the airflow, it 

is recommended that ventilation inlet and outlets consist of — 

(i) a number of holes spaced evenly along the side of the enclosure; or 

(ii) a slot running along the side of the room or enclosure. 

Battery enclosures should be designed to prevent the formation of pockets of gas. 

Ventilation outlets should be at the highest level in the battery enclosure. 

Ventilation inlets should be at a low level in the battery enclosures. Inlets should be 

no higher than the tops of the battery cells, and, where required, fitted with a coarse 

screen to prevent the entry of vermin. 

To ensure that airflow does not bypass a battery’s vents or valves, ventilation inlets 

(see Item (e) above) and outlets (see Item (d) above) should be on laterally opposite 

sides of the enclosure. 

Where mechanical ventilation is used, all exhaust air should be discharged outside 

the enclosure. 

If mechanical ventilation is installed, an airflow sensor shall be incorporated to 

initiate an alarm should the ventilation fan be inoperative. 

2.8 SAFETY SIGNS 

2.8.1 Explosion and electrolyte burns It is strongly recommended that a battery 

installation should have signs mounted in positions where they will be seen when the 

battery is approached. 

If used, the signs to be displayed shall— 

(a) for vented batteries, be the signs shown in Figures B1 and B2 of Appendix B; and 

(b) for valve-regulated batteries, be the sign shown in Figure B1 of Appendix B. 

2.8.2 Battery voltage and short-circuit current If the battery capacity exceeds 

100 A.h at the 120 h rate of discharge, or if the nominal battery voltage is in excess of 

extra-low voltage, suitable warning notices indicating battery voltage and the short-circuit 

current of the installation should be displayed. 

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SECTION 3 INSPECTION AND 

MAINTENANCE 


3.1 INSPECTION 

3.1.1 General The battery user should follow the inspection and maintenance schedule 

provided by the manufacturer or if none is available devise an inspection schedule 

appropriate to the importance and value of the battery installation. 

3.1.2 Test equipment The following test equipment may be required to perform 

inspection and maintenance: 

(a) Hydrometers —complying with AS 2562 and of a size that will enable access of the 

hydrometer syringe well into the battery cell and still allow the scale to be seen. 

NOTE: Hydrometers for use with vehicle starting batteries are not suitable for use with 

stand-alone batteries. 

(b) Thermometers — complying with AS 1006. 

(c) Ammeters, voltmeters and recorders — ammeters and voltmeters should be of the 

digital type for ease of reading during discharge. Digital voltmeters should have a 

readout of at least 31/2 digits because accurate reading of cell voltage to two decimal 

places is necessary for checking float voltage and for battery testing. Current and 

voltage recorders are recommended for ease of gathering data during battery 

capacity tests. 

(d) Torque wrench 

(e) Capacity tester —the capacity tester should, if possible, be portable, so that cells 

may be tested in position. The capacity tester may contain a load bank which 

radiates heat and may create a hazard in some locations. Capacity testing equipment 

should be designed so that it does not arc near the battery. 

3.1.3 Inspection schedule The results of all inspections should be recorded. Adequate 

battery records (previous maintenance procedures, environmental problems, system 

failures, and any corrective actions taken in the past) are an invaluable aid in determining 

battery conditions. 

It is preferable that all inspections be made on a fully charged battery. 

An inspection schedule should be drawn up in accordance with the battery manufacturer’s 

recommendations. 

The inspections listed below may be included in the schedule: 

(a) General appearance and cleanliness of the battery and battery area. 

(b) Battery and cell terminal voltages and charging current. 

(c) Electrolyte levels. 

(d) Cracks in the battery case or leakage of electrolyte. 

(e) The electrolyte density of each cell. 

(f) Intercell resistance. 

3.2 MAINTENANCE 

3.2.1 General Proper maintenance will prolong the life of a battery and will help to 

ensure that it is capable of satisfying its design requirements. A good battery maintenance 

program will serve as a valuable aid in determining the need for battery replacement, or in 

locating system faults. Only personnel who are familiar with battery installation, charging, 

and maintenance procedures should be permitted access to the battery area. The safety 

practices of Section 5 should be followed. 

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3.2.2 Corrective actions The following items are conditions that should be corrected 

at the time of inspection: 

(a) Correct low electrolyte levels and record the amount of water added. Water should 

be added to bring all cells to the high level line. Water quality should be in 

accordance with the manufacturer’s instructions. To avoid electrolyte overflow, 

water should be added only when it has been determined that the cells are in a fully 

charged condition. 

(b) Correct high connection resistances by disassembly and cleaning, then reassemble 

bolted connections to the torque specified by the manufacturer. High connection 

resistances are detected by localized heating or by excessive voltage drops. 

(c) If cell temperatures deviate from each other by more than the amount recommended 

by the manufacturer or supplier, the cause should be determined and corrected. 

(d) If the battery temperature is outside the range recommended by the manufacturer or 

supplier, the cause should be determined and corrected. 

(e) Remove excessive dirt or spilled electrolyte from the battery. 

(f) When the battery voltage is outside the manufacturer’s recommended range, the 

cause should be determined and corrected. 

(g) Any other abnormal conditions should be corrected in accordance with the 

manufacturer’s recommendations. 

3.2.3 Equalizing charges An equalizing charge, performed in accordance with the 

manufacturer’s instructions, may be required whenever any of the following conditions are 

found in lead-acid batteries. 

(a) The electrolyte density, corrected for temperature and electrolyte level, of an 

individual cell is more than 10 kg/m 3 below the average of all cells at the time of 

inspection. 

(b) The average electrolyte density, corrected for temperature and electrolyte levels, of 

all cells drops more than 10 kg/m 3 from the average installation value when the 

battery is fully charged. 

(c) For valve-regulated cells, if the float voltage per cell varies by an amount in excess 

of the manufacturer’s recommendation. 

These conditions, if allowed to persist for extended periods, can reduce battery life. They 

do not necessarily indicate a loss of capacity. Equalizing charges are not normally given 

to nickel-cadmium batteries. 

CAUTION: THE EQUALIZING VOLTAGE MAY PRESENT A 

OTHER CONNECTED EQUIPMENT. 

HAZARD TO 

3.3 EARTH FAULT LOCATION Where an earth-fault has occurred on a circuit 

employing an earth-leakage relay, each d.c. distribution circuit should be isolated in turn 

until all faults have been isolated. 

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SECTION 4 INSTALLATION AND 

COMMISSIONING 


4.1 UNPACKING Recommendations for unpacking are as follows: 

(a) Cells should never be lifted by the terminal posts. 

(b) Large cells that require mechanical lifting should be lifted using a sling or cradle 

that presents no danger of a short-circuit across the terminal posts. 

(c) The electrolyte level of filled cells should be checked. If filled cells are received 

with the electrolyte level below the plates, the supplier should be contacted. 

(d) The vent plugs should be checked for damage. If cells are fitted with transit plugs, 

they should be replaced with vent plugs as soon as possible. 

(e) If cells are received with visible defects, such as cracked containers, loose terminal 

posts, or improperly aligned plates, the supplier should be contacted. 

NOTE: The Australian code for the transport of dangerous goods by road and rail contains 

requirements for the packaging and transport of batteries. 

4.2 STORAGE The manufacturer’s instructions on storage should be followed at all 

times. If cells are charged during storage, the date and conditions of each charge should 

be recorded. 

4.3 MOUNTING AND CONNECTION The following steps should be carried out: 

(a) Tools and equipment should be in accordance with Section 5. 

(b) The battery should be checked to see that the appropriate warning labels are in 

place. 

(c) The battery stand or enclosure should be prepared in accordance with the 

manufacturer’s instructions. 

(d) Corrosion inhibiting material should be applied in accordance with the 

manufacturer’s instructions as follows: 

(i) Conducting grease should be applied to the battery terminals before 

connections are made; or 

(ii) Non-conducting grease should be applied to the terminals and connectors 

after connection has been made. 

(e) Individual cells should be lifted into position (see Clause 4.1, Items (a) and (b)). 

(f) Cells should be checked to see that they are correctly positioned for positive and 

negative connections throughout the battery. 

(g) Inter-cell connections should be made in accordance with the manufacturer’s 

instructions. If more than one inter-cell connector per through-connection is 

required, they should be mounted on opposite sides of the terminal for maximum 

surface contact. 

(h) All connection bolts should be tightened to the battery manufacturer’s recommended 

torque value. 

(i) All shrouds and cell covers should be cleaned. Dust and dirt should be removed 

with a clean disposable wiper moistened with water. Spilled electrolyte should be 

removed with a clean disposable wiper moistened with— 

(i) a solution of bicarbonate of soda when cleaning lead-acid batteries; and 

(ii) a very dilute solution of boric acid when cleaning nickel-cadmium batteries. 

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(j) 

(k) 

Each cell should be marked with a cell number beginning with number 1 at the 

positive end of the battery. Any required operating identification should be added. 

The voltage of the battery should be checked to ensure that individual cells are 

connected correctly, that is, the battery voltage should be equal to the voltage of 

one cell multiplied by the number of cells in series. If the battery voltage is less, the 

cell polarities should be rechecked and rectified in series, if necessary. 


4.4 COMMISSIONING 

4.4.1 Initial charge If required, a battery should receive an initial charge in 

accordance with the manufacturer’s or supplier’s recommendation. 

NOTE: If recommendations are not available the procedures outlined in Appendices C, D E or F 

should be followed. 

4.4.2 Dry-charged batteries Dry-charged batteries must be activated and charged in 

accordance with the manufacturer’s instructions before initial charging. 

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SECTION 5 SAFETY 


5.1 GENERAL The safety precautions listed in this Section should be followed during 

battery installation and maintenance. Work performed on batteries should be done only 

with insulated tools, and the protective equipment listed in Clause 5.3. 

Battery installation should be performed or supervised by staff experienced in battery 

installation maintenance and safety. 

Work performed on a battery in service should use methods which preclude circuit 

interruption or arcing in the vicinity of the battery. 

Access to battery rooms and enclosures should be restricted to authorized personnel. 

5.2 HANDLING, MIXING AND STORING OF ELECTROLYTE 

5.2.1 Acid electrolyte Acid electrolyte is usually supplied at approximately the 

concentration at which it is to be used. When it is supplied as a concentrated liquid it 

shall only be diluted by adding the concentrate to water while stirring, never by adding 

water to the concentrate. 

Acid electrolyte shall be stored in vessels lined with materials inert to acid; for example, 

acid-resistant plastics, glass, hard rubber, or lead. Metals other than lead should not be 

used. 

5.2.2 Alkaline electrolyte Alkaline electrolyte shall be stored only in a vessel lined 

with materials inert to alkali; for example clean steel and some alkali-resistant plastics. 

Alkaline electrolyte should be stored in airtight containers because atmospheric 

contamination can degrade the electrolyte. 

5.3 PROTECTIVE EQUIPMENT The following equipment for safe handling of the 

battery and protection of personnel may be required: 

(a) Combination overalls or dust coat (acid resistant). 

(b) Bib apron (PVC). 

(c) Boots (PVC). 

(d) Gloves (PVC fabric base). 

(e) Face shield or goggles. 

(f) Running water or water containers for rinsing eyes and skin in case of electrolyte 

spillage. 

(g) Bicarbonate of soda for acid electrolyte spills, or boric acid for alkaline electrolyte 

spills, or other suitable neutralizing agent recommended by the manufacturer. 

(h) Cell lifting devices of adequate capacity. 

(i) Appropriate hand tools with insulated handles. 

On routine inspection and maintenance work, where large quantities of electrolyte are not 

handled, combination overalls or a dust coat and face shield or goggles should be worn. 

5.4 ELECTROLYTE BURNS 

5.4.1 General The primary treatment for all electrolyte burns, whether acid or alkaline, 

is the immediate washing of the affected part with water to dilute the electrolyte. It is 

therefore essential that an adequate supply of clean water be available at all times. 

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Protective clothing should be worn at all times when in a battery room or when working 

near a battery enclosure. 

Any spilled electrolyte should be diluted or neutralized immediately and removed. 

Unprotected hands and clothing should be kept away from cells at all times. 

The battery containers, particularly the tops, should be kept clean and free of electrolyte. 

When electrolytes are being prepared, the battery manufacturer’s recommended procedures 

should be followed. 

Spilt electrolyte can be diluted by copious quantities of water, or neutralized by the 

addition of bicarbonate of soda (to acid electrolyte) or boric acid (to alkaline electrolyte). 

5.4.2 First aid treatment If an electrolyte splashes in the eye, the aim of first aid 

treatment is to dilute and eliminate the acid or alkali by flooding the eye immediately 

with water. Following irrigation of the eye, immediate medical attention should be sought. 

5.5 WATER SUPPLY An adequate supply of fresh water should be kept near the 

battery during installation and maintenance. 

5.6 PRECAUTIONS 

5.6.1 General Hydrogen and oxygen gases are released when a cell or battery is on 

charge and the volume of gas produced increases considerably near full charge. Hydrogen 

mixed with air in a proportion between 4% and 76% hydrogen in air by volume is 

combustible, and burning is enhanced by oxygen enrichment. 

Sources of ignition, such as sparks produced by static discharges, smoking, naked flames, 

and arcs from electrical equipment, should not be located in close proximity to the tops of 

cells. Static discharges can be caused by synthetic clothing and wiping rags. 

When a battery is on charge, bubbles may be released which can produce a corrosive mist. 

This should be controlled by ventilation and by the use of splash or baffle plates which 

should always be kept in position. 

5.6.2 During installation The following safety procedures should be followed prior to, 

and during, installation: 

(a) All lifting equipment should be inspected for functional adequacy. 

(b) Entry of unauthorized personnel to the battery area should be prohibited. 

(c) Smoking, the operation of electric hand tools, the use of open flame and the 

operation of equipment that produces electric arcs shall be prohibited in the 

immediate vicinity of the battery unless special precautions are taken. 

(d) The top of the battery shall be kept clear of all tools and other foreign objects. 

(e) Adequate illumination should be provided. 

(f) Exit from the battery area shall be unobstructed. 

(g) The battery area ventilation shall be operable during charging. 

(h) Combustible materials and heat sources should be kept away from a battery while 

charging. 

5.6.3 During maintenance The following precautions should be observed during 

maintenance: 

(a) The handles of tools should be insulated and ladders should be of non-metallic 

material. 

(b) Test equipment leads should be firmly connected with sufficient length of cable to 

prevent accidental arcing in the vicinity of the battery. 

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(c) 

(d) 

(e) 

(f) 

All connections to load test equipment should include short-circuit protection. 

Battery area ventilation shall be operable during charging. 

Exit from the battery area shall be unobstructed. 

Smoking, the operation of electric hand tools, the use of open flames and the 

operation of equipment that produces electric arcs shall be prohibited in the 

immediate vicinity of the battery unless special precautions are taken. 

5.7 FIREFIGHTING EQUIPMENT All battery installations should be provided with 

portable fire extinguishers selected in accordance with AS 2444 and suitable for use on 

acid and alkaline solutions and electrical fires. Extinguishers should be located adjacent to 

battery enclosures. It is essential that the provision of firefighting equipment complies 

with the requirements of the appropriate regulatory authority. 

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APPENDIX A 

DESIGN CONSIDERATIONS FOR BATTERY INSTALLATIONS 

(Informative) 


A1 SCOPE This Appendix covers a number of matters that should be considered when 

designing a battery installation. 

A2 OPERATING CONDITIONS The conditions under which a battery is operated 

affect the capacity of a battery. 

Important factors that reduce the capacity of a battery below the rated capacity are as 

follows: 

(a) Low temperatures reduce the actual capacity of a battery below its rated capacity. 

(b) A higher rate of discharge than the rate used in specifying rated capacity reduces 

the actual capacity. 

(c) Maintaining a higher final cell voltage than that used by the manufacturer to 

determine rated capacity will result in a decrease in actual capacity. 

NOTE: Operation of a battery in ambient temperatures above that used by the manufacturer to 

specify the life of the battery may result in reduced battery life. 

A3 DIRECT CURRENT SWITCHBOARDS Because of the high prospective fault 

current of batteries, d.c. switchboards used in conjunction with a battery should be 

designed in accordance with the following recommendations: 

(a) All switchgears (e.g. combination of fuse-switch units, moulded case circuitbreakers 

and isolators) should be of such a design that the occurrence of an internal 

arc fault is minimized. 

(b) Direct current switchboards of rated current greater than 100 A or prospective shortcircuit 

current greater than 5 kA should comply with AS 3439.1. 

(c) Direct current switchboards with prospective fault levels in excess of 20 kA should 

be designed for increased security against the occurrence of or the effects of internal 

arcing faults in accordance with the guidance provided in AS 3439.1. 

A4 EARTHING AND EARTH-FAULT DETECTION There are two basic 

installation schemes for d.c. systems using batteries. These are as follows: 

(a) The unearthed d.c. system in which neither pole of the battery is connected to earth. 

A non-galvanically isolated, i.e. transformerless, unearthed d.c. system, when 

supplied from a mains supply earthed by the MEN system in accordance with 

AS 3000, will have one terminal of the battery referenced at half nominal voltage to 

the installation earth. Work on a battery in such a system should be carried out with 

the battery isolated from the battery charger, if the nominal battery voltage exceeds 

110 V. 

(b) The solidly earthed d.c. system, where either the positive or negative pole of the 

battery, is connected directly to earth. 

NOTES: 

1 The unearthed d.c. system (Item (a) above) is the only one suitable for systems supplying 

a.c. The solidly earthed system (Item (b) above) is suitable only for systems supplying d.c. 

2 Appendix G shows typical direct current system earthing. 

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The advantage of an unearthed floating system is that it is not necessary to disconnect the 

supply in the event of a single earth-fault. It is only after the occurrence of a second 

earth-fault that a dangerous situation may arise and the supply must be disconnected. An 

unearthed system should be fitted with an alarm to indicate the presence of an earth-fault. 

Typical earth-fault relay operating currents are as follows: 


Direct current system voltage 

V 

Earth fault relay operating current 

mA 

50 5 

110 10 

200 30 

A5 VOLTAGE DROP The maximum allowed voltage drop between the battery 

terminals and the d.c. load (usually 5%), rather than current-carrying capacity, will 

determine the size of the conductors for some installations. 

The smallest conductor that will satisfy a maximum voltage drop requirements is the 

smallest that will satisfy the equation— 

V c 

= 1000V h 

L × I f 

...A5 

where 

V c = voltage drop over the route length of the circuit as shown in manufacturers’ 

tables for various conductors, in millivolts per ampere metre (mV/A.m). 

V h = maximum voltage drop, in millivolts per ampere metre (See Table A1) 

L = route length of the circuit, in metres 

= full load current, in amperes 

I f 

TABLE A1 

VOLTAGE DROP FACTORS FOR 

1AND2COREFLEXIBLECABLES 

Conductor area 

mm 

6 

10 

16 

25 

35 

50 

70 

95 

120 

150 

185 

Voltage drop V h 

mv/A.m 

8.25 

4.92 

3.00 

1.82 

1.35 

1.02 

0.688 

0.552 

0.444 

0.368 

0.322 

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A6 BATTERY STANDS Recommendations for battery stands are as follows: 

(a) The deflection, after installation and after normal settlement has taken place under 

load, should not be more than 3 mm. 

(b) The projected area of the base of the cell should be contained within the stand. 

(c) A space of at least 300 mm should be provided on one side of each cell to permit 

access to the cell. 

(d) The overall height of the battery installation should not exceed 2 m. 

(e) Horizontal restraining bars should be installed at the front and back of the battery 

stands, if the height of the battery is its greatest dimension. 

(f) The consequences of seismic activity should be considered. 

(g) The stand should be painted with an electrolyte resistant paint or similar material. 

A7 SHORT-CIRCUIT PERFORMANCE OF CABLES Cables used in a battery 

installation should be capable of sustaining the current that can flow as a result of a shortcircuit. 

Guidance on the permissible short circuit performance in the current-carrying 

components of a cable is given in Appendix H. 

A8 SERVICE TEST A service test is a special battery capacity test which may be 

required to determine if the battery will meet the requirements (battery duty cycle) of the 

stand-alone system and to determine the load which can be used with the system. The 

stand-alone system-designer should establish the test procedure and performance criteria 

prior to the test. 

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APPENDIX B 

SAFETY SIGNS 

(Normative) 


Type 

A 

Approx. dimensions 

mm 

1: for wall mounting 250 250 

2: for enclosures 175 175 

B 

NOTE: Danger symbol as in AS 1319. 

FIGURE B1 

TYPICAL REGULATORY SIGN (EXPLOSION) 

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NOTES: 

1 White lettering on background of green in accordance with AS 1319. 

2 Green lettering, white background. 

3 White lettering. 

DIMENSIONS IN MILLIMETRES 

FIGURE B2 TYPICAL EMERGENCY-RELATED INFORMATION SIGN (ELECTROLYTE) 

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APPENDIX 

INITIAL CHARGING AND COMMISSIONING OF 

VENTED LEAD-ACID BATTERIES 


C 


C1 SCOPE This Appendix sets out procedures for the initial charging and 

commissioning of vented lead-acid batteries according to their condition on delivery, if 

instructions are not available from the battery manufacturer or supplier. 

C2 CONDITION ON DELIVERY Lead-acid batteries are usually supplied from the 

manufacturer in one of the following conditions: 

(a) Fully charged, equalized and capacity proven. 

(b) Fully charged and equalized. 

(c) Unfilled, with or without, electrolyte in separate packs. 

C3 FULLY CHARGED, CAPACITY-PROVEN BATTERIES The following 

procedure should be carried out for batteries received from the manufacturer in a fully 

charged, equalized and capacity proven condition. 

(a) Connect the battery to a constant-voltage charger set to charge at 2.35 V to 2.4 V 

per cell for 120 h rated batteries. 

(b) Continue charging until all cells are gassing (not more than 12 h charging should be 

necessary). Any cells which do not gas and vary by 0.05 V or more from the mean 

should be referred to the manufacturer for rectification. 

(c) Reduce the charger potential to float the battery at 2.25 V to 2.28 V per cell for 

10 h rated batteries, and at 2.3 V to 2.33 V per cell for 1 h rated batteries. Allow 

24 h for the battery to stabilize on float. 

(d) Check and record in the battery log book all cell voltages and electrolyte densities. 

NOTE: If circumstances permit, batteries can be charged in the constant current mode, in 

accordance with the manufacturer’s instructions. 

C4 FULLY CHARGED BATTERIES Fully charged batteries may deliver 85% or 

more of their rated capacities, however, the densities of the electrolyte in all cells should 

not differ by more than 10 kg/m 3 . 

The following procedure should be carried out for batteries received from the 

manufacturer in a fully charged, equalized condition: 

(a) Connect the installed battery to a constant potential charger as in Paragraph C3(a) 

and charge until gassing. 

(b) Reduce the charger potential to float the battery at 2.25 V to 2.28 V per cell for 

10 h rated batteries, and at 2.3 V to 2.33 V per cell for 1 h rated batteries. Allow 

24 h for the battery to stabilize on float. 

(c) Check and record in the battery log book all cell voltages and electrolyte densities. 

C5 UNFILLED BATTERIES Unfilled batteries are given a substantial charge but due 

to processing, storage and transport, the state of charge of the batteries when delivered 

varies widely. The following procedure should be carried out for batteries received from 

the manufacturer in an unfilled charged condition: 

(a) If the electrolyte is not supplied, it should be prepared in accordance with the 

manufacturer’s instructions using sulphuric acid and water complying with AS 2669 

and AS 2668 respectively. 

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(b) Remove the seals over the filler holes of the cells and fill to the low-level marks on 

the cell containers. 

(c) Allow the battery to stand until the electrolyte cools to a maximum of 40°C and 

adjust the electrolyte levels. 

(d) Connect the battery to a battery charger capable of supplying a voltage in the range 

2.6 V to 2.9 V per cell. This is required to fully develop the cell. Charge the battery 

at the manufacturer’s recommended voltage and rate, and monitor the electrolyte 

temperature. Discontinue charging if the electrolyte temperature exceeds 45°C. 

(e) Carry out a performance check of the battery capacity in accordance with Appendix 

I. If the battery capacity is 85% or more of the rated capacity, recharge the battery 

in accordance with Paragraph C3 Steps (a) to (c) and then carry out the procedure in 

Paragraph C3(d). If the battery capacity is less than 85% of rated capacity, proceed 

to Step (f). 

(f) Recharge the battery in accordance with Paragraph C3(a) then carry out a 

performance check of the battery in accordance with Appendix I. If the battery 

capacity after the second test discharge is 85% or more of the rated capacity, 

recharge the battery in accordance with Paragraph C3 Steps (a) to (c) and then carry 

out the procedure in Paragraph C3(d). If the battery capacity after the second test 

discharge is less than 85% of rated capacity, the battery manufacturer should be 

consulted. 

C6 INTER-CELL CONNECTIONS The integrity of all connections, from cell post to 

cell post, should be verified during commissioning by the use of a voltmeter accurate to 

1 mV. The voltage drop across connectors should not be more than 5 mV when carrying a 

current equal to the 10 h rate. 

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APPENDIX 

INITIAL CHARGING AND COMMISSIONING OF VENTED 

NICKEL-CADMIUM ALKALINE BATTERIES 


D 


D1 SCOPE This Appendix sets out procedures for the initial charging and 

commissioning of nickel-cadmium alkaline batteries according to their condition on 

delivery, if instructions are not available from the battery manufacturer or supplier. 

D2 CONDITION ON DELIVERY Alkaline batteries are usually supplied from the 

manufacturer in one of the following conditions: 

(a) Filled and charged The battery is supplied filled with electrolyte, and fully 

charged ready for use within 12 months. 

(b) Empty and discharged The battery has been charged but is supplied discharged and 

empty of electrolyte to facilitate storage. 

NOTE: It is essential for empty and discharged cells to be filled and charged immediately after 

removing the seals from the cell opening. 

D3 FILLED AND CHARGED BATTERIES The following procedures should be 

carried out for batteries received from the manufacturer which have been filled with 

electrolyte and fully charged: 

(a) Batteries entering service less than three months after shipment from the 

manufacturer or supplier should be boost charged because all batteries should enter 

service fully charged. 

(b) Between three months and 12 months after shipment from the manufacturer or 

supplier it is necessary that batteries be boost charged, preferably after being 

discharged at the C 5 A rate down to 1.0 volts per cell. 

(c) Check and record all cell voltages in the log book. 

D4 EMPTY AND DISCHARGED BATTERIES The following procedures should be 

carried out for batteries received from the manufacturer in an empty and discharged 

condition: 

(a) Prepare the electrolyte in accordance with the manufacturer’s instructions. 

(b) Remove the seals over the filler holes of the cells. 

(c) Fill the cells to the correct level with the electrolyte. 

(d) Allow the battery to stand for at least 30 min after filling and adjust the electrolyte 

level. 

(e) Charge at the current, and for the time, recommended by the manufacturer. 

Discontinue charging if the electrolyte temperature exceeds 45°C. 

(f) Check the electrolyte density and adjust in accordance with the manufacturer’s or 

supplier’s instructions or to 1180 ±10 kg/m 3 , if no instructions are available. After 

the final adjustment, the quantity of electrolyte in the battery is correct and the 

battery is ready for testing. No electrolyte should be added later. 

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(g) Carry out a performance check of the battery capacity in accordance with 

Appendix I. If the battery capacity is 85% or more of the rated capacity, recharge 

the battery in accordance with Step (e) and then carry out the procedure in 

Paragraph D3(c). If the battery capacity is less than 85% of rated capacity, proceed 

to Step (h). 

(h) Recharge the battery in accordance with Step (e) then carry out a performance check 

of the battery in accordance with Appendix I. If the battery capacity after the second 

test discharge is 85% or more of the rated capacity, recharge the battery in 

accordance with Step (e) and then carry out the procedure in Paragraph D3(e). If the 

battery capacity after the second test discharge is less than 85% of rated capacity, 

the battery manufacturer should be consulted. 

D5 INTER-CELL CONNECTIONS The integrity of all connections, from cell post to 

cell post, should be verified during commissioning by the use of a voltmeter accurate to 

1 mV. The voltage drop across connectors should not be more than 5 mV when a current 

equal to the 10 h rate of the battery is flowing. 

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APPENDIX 

INITIAL CHARGING AND COMMISSIONING OF VALVE-REGULATED 

NICKEL-CADMIUM BATTERIES 


E 


E1 SCOPE This Appendix sets out procedures for the initial charging and 

commissioning of valve-regulated nickel-cadmium batteries (gas recombination type), 

according to their condition on delivery. 

E2 CONDITION ON DELIVERY Valve-regulated nickel-cadmium batteries are 

supplied from the manufacturer in a fully charged condition. 

E3 INITIAL CHARGING The following procedure should be carried out for batteries 

received from the manufacturer: 

(a) Batteries going immediately into service are usually able to be placed on float duty 

without any initial charge. The manufacturer’s recommendations should be 

followed. 

(b) Batteries not to be installed within three months should be stored in accordance with 

Clause 4.2. 

(c) Batteries requiring a performance test in accordance with Appendix I before going 

into service should be given a refresher charge before the test and immediately 

before being placed in service. 

The refresher charger should be in accordance with the manufacturer’s 

recommendations and is typically at a constant voltage equivalent to 1.40 V to 

1.47 V per cell and is maintained until 160% of the rated capacity of the battery has 

been applied. 

The battery may be considered fully charged when, under constant voltage 

conditions, the current passing through the battery has not changed for three 

consecutive readings taken at 2 h intervals, allowance being made for the battery 

temperature. 

(d) The following should be recorded: 

(i) The charge current, the total voltage across the battery and the ambient 

temperature during float charging operations. 

(ii) Full details of any performance test in accordance with Appendix I. 

E4 SERVICE TEST When required, a service test of the battery capacity should be 

carried out in accordance with Paragraph A8. This should be done upon completion of the 

installation to meet a specified requirement. 

E5 INTER-CELL CONNECTIONS The integrity of all connections, from battery 

post to battery post, should be verified during commissioning by the use of a voltmeter 

accurate to 1 mV. The connector voltage drop should not be more than 5 mV when a 

current equal to the 10 h rate of the battery is flowing. 

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APPENDIX 

INITIAL CHARGING AND COMMISSIONING OF VALVE-REGULATED 

LEAD-ACID BATTERIES 


F 


F1 SCOPE This Appendix sets out procedures for the initial charging and 

commissioning of valve-regulated lead-acid batteries (gas recombination type), according 

to their condition on delivery. 

F2 CONDITION ON DELIVERY Valve-regulated lead-acid batteries are supplied 

from the manufacturer in a fully charged condition. 

F3 INITIAL CHARGING The following procedure should be carried out for batteries 

received from the manufacturer: 

(a) Batteries going immediately into service are usually able to be placed on float duty 

without any initial charge. The manufacturer’s recommendations should be 

followed. 

(b) Batteries not to be installed within three months should be stored in accordance with 

Clause 4.2 

(c) Batteries requiring a performance test in accordance with Appendix I before going 

into service should be given a refresher charge before the test and immediately 

before being placed in service. 

The refresher charger should be in accordance with the manufacturer’s 

recommendations and is typically at a constant voltage equivalent to 2.27 V per cell 

for a period of between 48 h and 72 h. 

The battery can be considered fully charged when, under constant voltage 

conditions, the current passing through the battery has not changed for three 

consecutive readings taken at 2 h intervals, allowance being made for the battery 

temperature. 

(d) The following should be recorded: 

(i) The charge current, the total voltage across the battery and the ambient 

temperature during float charging operations. 

(ii) Full details of any performance test in accordance with Appendix I. 

F4 SERVICE TEST When required, a service test of the battery capacity should be 

carried out in accordance with Paragraph A8. This should be done upon completion of 

the installation to meet a specified requirement. 

F5 INTER-CELL CONNECTIONS The integrity of all connections, from battery 

post to battery post, should be verified during commissioning by the use of a voltmeter 

accurate to 1 mV. The connector voltage drop should not be more than 5 mV when a 

current equal to the 10 h rate of the battery is flowing. 

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APPENDIX G 

TYPICAL DIRECT CURRENT SYSTEM EARTHING 



FIGURE G1 

POSITIVE SOLIDLY EARTHED 

FIGURE G2 

NEGATIVE SOLIDLY EARTHED 

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APPENDIX H 

SHORT-CIRCUIT PERFORMANCE OF CABLES 



H1 SCOPE This Appendix covers the short-circuit maximum temperature rating of 

output conductors in a battery installation. 

H2 BATTERY SHORT-CIRCUIT CURRENT The requirements for a high discharge 

current for short periods have resulted in the development of cells with low internal 

resistance and high discharge current capability. A typical vented lead-acid stationary 

battery with a nominal capacity of 200 A.h is capable of delivering a short-circuit current 

of 2000 A. 

The battery manufacturer should be consulted with regard to the sizing of battery 

short-circuit protection. If information regarding the short-circuit protection of a battery is 

not available from the manufacturer, the prospective fault level at the battery terminals 

should be considered to be 6 times the nominal battery capacity at the 120 h rate. 

The short-circuit current rating of a battery consisting of strings of cells in parallel is the 

sum of the short-circuit current ratings of a group of cells comprising a single cell from 

each of the parallel branches. A monobloc battery consisting of a number of cells in series 

can be treated as a single cell for the purpose of determining short-circuit current rating. 

H3 FACTORS GOVERNING THE APPLICATION OF THE TEMPERATURE 

LIMITS The short-circuit temperatures given in Paragraph H6 are the actual 

temperatures of the current-carrying components as limited by the adjacent materials in 

the cable and are valid for short-circuit durations of up to 5 s. These temperatures will 

only be obtained in practice if non-adiabatic heating is assumed (that is, if an appropriate 

allowance is made for heat loss into the dielectric during the short circuit) when 

calculating the allowable short-circuit current for a given time (not longer than 5 s). The 

use of the adiabatic method (that is, when heat loss from the current-carrying component 

during the short circuit is neglected) gives short-circuit currents that are on the safe side. 

The 5 s period is the limit for the temperatures to be valid, not for the application of the 

adiabatic calculation method. The time limit for the use of the adiabatic method has a 

different definition, being a function of both the short-circuit duration and the 

cross-sectional area of the current-carrying component. 

For thermoplastic insulating materials, the limits must be applied with caution when the 

cables are either directly buried or securely clamped when in air. Local pressure due to 

clamping or the use of an installation radius less than 8 times the cable’s outside 

diameter, especially for cables that are rigidly restrained, can lead to high deforming 

forces under short-circuit conditions. Where these conditions cannot be avoided, it is 

suggested that the limit be reduced by 10°C. The limits quoted are based on average 

hardness grades of PVC and some adjustment may be necessary for other grades, 

especially those compounded for improved low-temperature properties. 

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NOTES: 

1 Caution should be exercised when using the limits recommended for thermosetting materials 

on large conductors because the high mechanical forces combined with any residual 

characteristics could result in deformation sufficient to cause failure. 

2 Caution may be needed with total cross-sectional areas in the region of 1000 mm 2 when 

using the conductor temperatures specified for impregnated paper, butyl, cross-linked 

polyethylene (XLPE) and ethylene propylene rubber (EPR) insulation and the cable is 

sheathed with a lower-temperature material. 

3 Information on the short-circuit performance of mineral-insulated metal sheathed cables is 

not included in this Standard and reference should be made to the manufacturer’s 

recommendations. 

H4 CALCULATION OF PERMISSIBLE SHORT-CIRCUIT CURRENTS The following 

adiabatic method, which neglects heat loss, is accurate enough for calculating permissible 

conductor and metallic sheath short-circuit currents for the majority of practical cases and 

any error is on the safe side. However, for thin screens, the adiabatic method indicates 

much higher temperature rises than actually occur in practice and thus must be used with 

some discretion. 

The generalized form of the adiabatic temperature rise equation which is applicable to any 

starting temperature is as follows: 

I 2 t = K 2 S 2 

...H4 

where 

I = short-circuit current (r.m.s. over duration), in amperes 

t = duration of short circuit, in seconds 

K 

S 

= constant depending on the material of the current-carrying component, the initial 

temperature and the final temperature 

NOTE: Refer to Table H1 for values of constant (K). 

= cross-sectional area of the current-carrying component, in square millimetres. 

NOTE: For conductors and metallic sheaths it is sufficient to take the nominal 

cross-sectional area but in the case of screens, this quantity requires careful 

consideration. 

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TABLE H1 

VALUES OF CONSTANT K FOR DETERMINATION OF 

PERMISSIBLE SHORT-CIRCUIT CURRENTS 


Initial temp. 

of conductor 

Constant (K) 

Final temperature of conductor, °C 

Copper Aluminium Lead Steel 

°C 140 150 160 220 250 350 130 150 160 250 130 150 250 130 150 170 

130 

125 

90 

85 

80 

75 

70 

65 

60 

55 

50 

45 

40 

35 

30 

37.2 

45.7 

85.6 

90.1 

94.4 

98.7 

103 

107 

111 

115 

118 

122 

126 

130 

133 

52.2 

58.6 

93.1 

97.3 

101 

105 

109 

113 

117 

120 

124 

128 

131 

135 

138 

63.6 

68.9 

99.9 

104 

108 

111 

115 

119 

122 

126 

129 

133 

136 

140 

143 

106 

109 

131 

134 

137 

140 

143 

146 

149 

152 

155 

158 

160 

163 

166 

121 

123 

143 

146 

149 

151 

154 

157 

159 

162 

165 

168 

170 

173 

176 

155 

158 

173 

176 

178 

180 

182 

185 

187 

189 

192 

194 

196 

199 

201 

— 

17.6 

50.9 

54.2 

57.4 

60.4 

63.4 

66.2 

69.0 

71.8 

74.4 

77.1 

79.6 

82.2 

84.7 

34.5 

38.7 

61.5 

64.3 

67.0 

69.6 

72.2 

74.7 

77.2 

79.6 

82.0 

84.4 

86.8 

89.1 

91.5 

25 137 142 146 169 179 204 87.2 93.8 96.8 118 24.1 25.9 32.6 48.1 51.7 54.8 

H5 INFLUENCE OF METHOD OF INSTALLATION When it is intended to make 

full use of the short-circuit limits of a cable, consideration should be given to the 

influence of the method of installation. An important aspect concerns the extent and 

nature of the mechanical restraint imposed on the cable. Longitudinal expansion of a cable 

during a short circuit can be significant and when this expansion is restrained the resultant 

forces are considerable. 

Where cables are installed in air, provision should be made so that expansion may be 

absorbed uniformly along the length by snaking rather than permitting it to be relieved by 

excessive movement at a few points only. Fixings should be spaced sufficiently far apart 

to permit lateral movement of multi-core cables or groups of single-core cables. 

Where cables are buried directly in the ground, or must be restrained by frequent fixing, 

then provision should be made to accommodate the resulting longitudinal forces on 

terminations and joint boxes. Sharp bends should be avoided because the longitudinal 

forces are translated into radial pressures at bends in the cable route and these may 

damage thermoplastic components of the cable such as insulation and sheaths. Attention is 

drawn to the minimum bending radius recommended by the appropriate installation 

regulations. For cables in air, it is also desirable to avoid fixings at a bend which may 

cause local pressure on the cable. 

H6 MAXIMUM PERMISSIBLE SHORT-CIRCUIT TEMPERATURES 

H6.1 General Taking into account the recommendation given in Paragraph F3, the 

temperature values given in Tables F2 to F4 are — 

(a) the actual temperatures of the current-carrying components; and 

(b) the limits specified for short-circuits of up to 5 s duration. 

H6.2 Insulating materials The temperature limits given in Table F2 are for all types 

of conditions when in contact with the insulating materials specified. 

42.0 

45.5 

66.0 

68.6 

71.1 

73.6 

76.0 

78.4 

80.8 

83.1 

85.5 

87.7 

90.0 

92.3 

94.5 

79.6 

81.5 

94.5 

96.3 

98.1 

99.9 

102 

104 

105 

107 

109 

111 

113 

114 

116 

— 

4.8 

14.1 

15.0 

15.9 

16.7 

17.5 

18.3 

19.1 

19.8 

20.6 

21.3 

22.0 

22.7 

23.4 

9.5 

10.7 

17.0 

17.8 

18.5 

19.2 

19.9 

20.6 

21.3 

22.0 

22.7 

23.3 

24.0 

24.6 

25.3 

22.0 

22.5 

26.1 

26.6 

27.1 

27.6 

28.1 

28.6 

29.1 

29.6 

30.1 

30.6 

31.1 

31.6 

32.1 

— 

9.6 

27.9 

29.8 

31.5 

33.2 

34.8 

36.4 

38.0 

39.5 

41.0 

42.4 

43.9 

45.3 

46.7 

18.9 

21.2 

33.7 

35.2 

36.7 

38.2 

39.6 

41.0 

42.4 

43.7 

45.1 

46.4 

47.7 

49.1 

50.4 

26.3 

28.0 

38.4 

39.7 

41.1 

42.4 

43.6 

44.9 

46.2 

47.4 

48.7 

49.9 

51.1 

52.4 

53.6 

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TABLE H2 

TEMPERATURE LIMITS FOR INSULATING 

MATERIALS IN CONTACT WITH CONDUCTORS 

Material 

Temperature limit 

°C 


Paper 

PVC—V-75, zV-90 and V-105 

—up to and including 300 mm 

—greater than 300 mm 

Elastomer R75 

XLPE and R-EP-90 

Silicone rubber, R-S-150 

H6.3 Outer sheath and bedding materials The temperature limits given in Table F3 

are for the outer sheath and bedding materials comprising a continuous screen/sheath or a 

complete layer of armour wires. These temperatures are for materials where there is no 

electrical or other requirements necessary, i.e. screen/sheath/armour temperature limits 

when in contact with the outer sheath materials but thermally separated from the 

insulation by layers of suitable material of sufficient thickness. If thermal separation is 

not provided, the temperature limits of the insulation should be used if it is lower than 

that of the sheath. 

250 

160 

140 

200 

250 

350 

TABLE H3 

TEMPERATURE LIMITS FOR OUTER SHEATH 

AND BEDDING MATERIALS 

Material 

PVC—V-75, V-90 and V-105 

Polyethylene 

R-CPS-90 


°C 

H6.4 Conductor and metallic sheath materials and components The temperature 

limits specified in Table H4 apply to the conductor and metallic sheath materials and 

components. 

NOTE: Limitations of materials in contact with these metals should also be considered. 

200 

150 

220 

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TABLE H4 

TEMPERATURE LIMITS FOR CONDUCTOR AND METALLIC 

SHEATH MATERIALS AND COMPONENTS 

Metals 

Condition 


°C 


Copper and 

Conductor only* † 

aluminium 

Welded joint † 

Exothermic welded joint 250† 

Soldered joint 160 

Compression (mechanical deformation) 

250‡ 

joint 

Mechanical (bolted) joint § 

Lead 170 

Lead alloy 200 

Steel † 

* Includes concentric neutral conductors. 

† Limited by the material it is in contact with. 

‡ Temperature of adjacent conductor; actual joint will be at a lower temperature. 

§ Refer to manufacturer’s recommendations. 

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APPENDIX I 

PERFORMANCE TEST 



I1 SCOPE This Appendix sets out a procedure for the performance testing of a 

battery. 

I2 PRINCIPLE The battery, or a sample of cells, is discharged at its specified rate 

and its actual capacity as a percentage of its rated capacity, at 25°C, is determined. 

I3 PROCEDURE The procedure is as follows: 

(a) Set up a load with an ammeter and voltmeter connected in the circuit and with 

provision for the load to be varied to maintain a constant current discharge at the 

selected rate (see Figure I1). 

(b) Connect the load to the battery, starting the timing, and continue to maintain the 

selected discharge rate. 

(c) Maintain the discharge rate until the battery terminal voltage decreases to a value 

equal to the specified final voltage per cell multiplied by the number of cells. 

(d) Read and record individual cell voltages and the battery terminal voltage. Take a 

minimum of three readings while the load is applied at the beginning and the 

completion of the test and at specified intervals. 

NOTE: Individual cell voltage readings should be taken between respective posts of like 

polarity of adjacent cells, so as to include the voltage drop of the inter-cell connectors. 

(e) Measure and record the temperature of cells under test at regular intervals during 

the discharge cycle. Ensure that the number of cells selected for test is consistent 

with the ability to take measurements during the discharge period and includes at 

least one cell at the end of the battery string. Select other cells at equal intervals 

throughout the string. 

(f) Check the battery for inter-cell-connector heating by any suitable means. 

(g) Determine the percentage battery capacity in accordance with Paragraph I4. 

(h) Disconnect all test apparatus then, if necessary, give the battery a boost charge, then 

return it to float charge in accordance with the manufacturer’s recommendation. 

I4 CALCULATION Following a performance test the percentage capacity should be 

determined from the following equation: 

C 25°C 

where 

= C a 

C s 

× 100 

...I4(1) 

C 25°C = percentage capacity at 25°C, in ampere hours 

C a = actual tested capacity to specified terminal voltage, in ampere hours 

C s = rated capacity to specified terminal voltage at the same rate of discharge, in 

ampere hours 

NOTES: 

1 Battery capacity may be specified at temperatures other than 25°C. 

2 Correction for the effect of temperature on the capacity of batteries should be made using 

derating factors supplied by the manufacturer. 

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I6 REPORT The test report should contain the following: 

(a) The individual cell voltages and the battery terminal voltages. 

(b) The temperatures of cells under test during the discharge cycle. 

(c) Whether there was any inter-cell connector heating. 

(d) The percentage battery capacity. 

(e) Reference to this test method, i.e. AS 4086.2, Appendix I. 

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NOTE: SWB to SWG are operated as required to maintain a constant discharge current. 

FIGURE I1 

TYPICAL CAPACITY TESTER (AIR-COOLED RESISTOR LOAD BANK) 

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AS 4086.2-1997 Secondary batteries for use with stand-alone power ...

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