National Batteries Company
Warranty Diagnosis

Warranty Diagnosis

Dry Charged Batteries(Dc)
Three Steps Warranty/Failure Analysis for DC Batteries

Physical Observations

Step 1. INITIAL EXAMINATION
Checklist Status Decision
1 Proof of purchase Okay Not Okay Accept / Reject
2 Approved application Okay Not Okay Accept / Reject
3 With in warranty period Okay Not Okay Accept / Reject
4 Damaged/Corroded terminal Okay Not Okay Accept / Reject
5 Electrolyte below plate Okay Not Okay Accept / Reject
6 Heavy mud and oil of battery top Okay Not Okay Accept / Reject
7 Damaged battery casing Okay Not Okay Accept / Reject
8 Electrolyte sp. gr > 1.300 Okay Not Okay Accept / Reject
9 Discoloured Acid/Muddy or Dark in apperance Okay Not Okay Accept / Reject
10 Electrolyte sp. gr < 1.100 in all cells Okay Not Okay Accept / Reject
11 White plates vissible from the vent opening in all cells Okay Not Okay Accept / Reject
12 Black scum or oily deposition on the bottom of the vent plug. Okay Not Okay Accept / Reject
Note: If any one of the above 12 points is Not Okay then claim to be rejected.

Electrical Performance Test (HRD)

Step 2. DETAIL EXAMINATION
Case Voltmeter Reading High Rate Volts (HRD Tester) Hydrometer Reading Decision Action
1 10-11.5 Volts < 9 volts Any one or two or more not all six cell sp. gr. falls below 40 points compared to other Accept  
2 10-11.5 Volts > 9 volts Reject Charge
3 12.0-12.7 Volt < 3 volts (falls sharply) All cells have same level of electrolyte sp. gr. Accept  
4 0-11.5 Volt < 3 volts (falls slowly) Reject Charge
5 3 to 9 volt < 3 volts (falls slowly) Reject Charge

Charge Acceptance Test

Step 3. EXAMINATION DURING CHARGING
Charge Amps :- 10% of c-20 rated capacity.(N50 @ 5 Amps)
Duration :- Till 3 consequtive hourly reading of electrolyte sp. gr is constant.
(During charging Temp, Voltage & Electrolyte sp. gr to be monitored every 1/2 hour)
Case Observation Decision Action
1 If the Temp. during charging exceeds 60 Deg C. Stop charging Give rest/Cont. charging at low amps
2 If fumes are observed from any cell or any one cell is not gasing Stop charging/ Accept Waranty Send to Factory for failure Analysis.
3 If the voltage doesn't rise instead falls with charging with rise in temp. and the voltage less than 15.0 volts. (Only applicable for constant current charger)
4 If the electrolyte sp.gr less than 1.220 even after 24 hours of charging.(For constant Voltage & Constant current charging)
5 If the battery has got charged properly. Stop charging. Adjust the electrolyte with DM. Fit in the vehicle for cranking test.
Note: If above battery case 5 fails to to crank the vehicle then the vehicle eletrical system to be checked. and Warranty claim to be rejected
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