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 |