Chapter 17 (3)

1. The Exide Cell is shown in Fig. 324. It has a grooved wood separator between each positive and negative plate. The separators are kept from floating up by a glass "hold-down" laid across the top. The separators are provided at the top with a pin which rests on the adjoining plates. The pins together with the plate glass hold-downs keep the separators in Position.

To remove an element it is simply necessary to unbolt the connectors, remove the glass cover and hold-down and lift wit the element.

2. The Chloride Accumulator cell is shown in Fig. 323. It differs from the Exide only in type of plates and separators. The positive plates are known as Manchester positives and have the active material in the form of corrugated buttons which are held in a thick grid, as shown in Fig. 325. The buttons are brown in color, the same as all positive active material.

The separators, instead of being grooved wood, am each a sheet of wood with six dowels pinned to it.

The element is removed the same as in the Exide type.

[Fig. 323 Exide chloride accumulator cell with open glass jar,
and Fig. 324 Exide cell with open glass jar]

Batteries with Sealed Rubber Jars

1. The Exide cell is shown in Fig. 326. It is assembled similar to Exide starting and lighting batteries, except that the plates are considerably thicker, wood and rubber separators are used, and the terminal posts are shaped to provide for bolted instead of burned-on connection. The method of sealing and unsealing the cells is the same as in Exide starting and lighting batteries.

All instructions already given for glass for cells apply to rubber jar cells except for a few differences in assembling and disassembling.

Care should be taken to keep the water level at least 1/2 inch above plates at all times as the evaporation is very rapid in rubber jar cells.

The temperature should be watched on charging to prevent overheating. Never allow temperature to go above 110° F.

Unlike the glass jar cells the sediment space in the rubber jar is not sufficient to take care of all the active material in the positive plates. On repairs, therefore, always clean out the sediment and prevent premature short circuits.

[Fig. 325 Manchester positive plates, and
Fig. 326 Exide cell with sealed rubber jar]

WESTINGHOUSE FARM LIGHTING BATTERIES

Jars. Westinghouse Farm Lighting Battery jars are made of glass, with a 5/16 inch wall. The jars are pressed with the supporting ribs for the elements an integral part from a mass of molten glass. A heavy flange is pressed around the upper edge to strengthen the jar.

Top Construction. A sealed-in cover is used similar to that used in starting and lighting batteries. The opening around the post hole is sealed with compound.

Plates. Pasted plates are used. The positives are 1/4 inch thick, and the negatives 3/16 inch. Posts are 13/16 inch in diameter.

Separators. A combination of wood and perforated rubber sheets is used.

Opening and Setting-Up Westinghouse Farm Lighting Batteries

[Fig. 327 Westinghouse farm lighting cell]

It is preferable that the temperature never exceed 100 deg. Fahrenheit nor fall below 10 deg. in the place where the battery is set up. If the temperature is liable to drop below 10 degrees the battery should be kept in a fully charged condition.

1. Remove all excelsior and the other packing material from the top of the cells. Take cells out carefully and set on the floor. Do not drop or handle roughly. Be sure to remove the lead top connectors from each compartment.

2. Cells should be placed 1/4 inch apart. Also, cells should be placed alternately so that positive post of one cell is adjacent to negative post of the next cell. Positive post has "V" shape shoulder and the negative post has a square shoulder.

3. Grease all posts, straps and nuts with vaseline.

4. Connect positive posts of each cell to negative post of adjacent cell, using top connectors furnished. Top connectors are made so as to fit when connection is made between positive post of one cell and negative post of next cell. Use long connector between end cells of upper and lower shelves.

5. With all connections between cells in position, join the remaining positive post with a connection marked "Positive" leading from the electric generator. Do likewise with the remaining negative post.

6. If liquid level in any cell is 1 inch or more below the "Liquid Line" on side of glass jar, some liquid has been spilled and must be replaced. This should be done by an experienced person.

7. Immediately after installation operate electric generator and charge battery until gas bubbles rise freely through the liquid in all cells. A reading with the hydrometer syringe which is furnished with the battery should be taken, When the hydrometer float reads between 1.240 and 1.250, the battery is fully charged.

8. The time required to complete the charging operation mentioned above may vary from one to several hours, depending upon the length of time the battery has been in transit. During the charge the temperature of the cells should not be permitted to rise above 110 deg. Fahrenheit. If this condition occurs discontinue the charge or decrease the charge rate until cells have cooled off.

9. When charge is complete replace vent plugs.

The Relation Between Various Sizes of Westinghouse Farm Light Batteries and Work to be Done

The size of the battery furnished with complete farm lighting units vary greatly. Sometimes the battery size is varied with the size of the engine and generator, while again the same size of battery may be used for several sizes of engines and generators. In making replacements, while it is always necessary to retain the same number of cells, it is not necessary to retain the same size of cells.

Usually increasing the cell size increases the convenience to the owner and prolongs the life of the battery to an amount which warrants the higher cost.

With a larger battery, danger of injury through overcharging is lessened, the load on the battery is more easily carried and the engine and generator operate less frequently.

In order to give an idea of various battery capacities, below is a table showing the number of 32 volt, 25-watt lamps which may be lighted for various lengths of time from sixteen cells. The number of hours shows the length of time that the lamps will operate.

Table A

Type 3 Hours 5 Hours 8 Hours ---- ------- ------- ------- G-7 22 Lamps 14 Lamps 10 Lamps G-9 28 Lamps 19 Lamps 13 Lamps G-11 32 Lamps 24 Lamps 15 Lamps G-13 41 Lamps 29 Lamps 19 Lamps G-15 47 Lamps 33 Lamps 22 Lamps G-17 54 Lamps 38 Lamps 25 Lamps

Note:--Based on 32-Volt 25-Watt Lamps.

For example--The table shows opposite G-7 that, with the battery fully charged, twenty-two lamps may be lighted for three hours, fourteen lamps for five hours and ten lamps for eight hours, by a sixteen cell G-7 battery, without operating the engine and generator.

Motors for operating various household and farm appliances are usually rated either in horsepower or watts. The following table will give a comparison between horse-power and watts as well as the number of 25-watt lamps to which these different sizes of motors and appliances correspond.

Table B

H.P. of Motor No. of Watts Corresponding No. of 25-Watt Lamps ------------- ------------ -------------------- 1/8 93 4 1/4 185 7 1/2 373 15 3/4 559 22 1 H.P. 746 30

From table B it will be seen, for example, that a one horsepower motor draws from the battery 373 watts or the same power as do fifteen 25-watt lamps. Then referring to table A, it will be found that a G-11 battery could operate 15 lamps or this motor alone for 8 hours.

Due to the fact that a motor or electric appliance may become overloaded and therefore actually use many more watts than the name plate indicates, it is not advisable to operate any motor of over 1/4 H. P. or even an appliance of over 186 watts on the G-13 or smaller sizes unless the engine and generator are running.

It is safe, however, to operate motors or other appliances up to 375 watts on the G-15 or G-17 batteries without operating the engine and generator.

WILLARD FARM LIGHTING BATTERIES

[Fig. 328 Willard Farm Lighting Cell]

The Willard Storage Battery Co. manufactures farm lighting batteries which use sealed glass jars, or sealed rubber jars. Those using the sealed glass jars include types PH and PA. The sealed rubber jar batteries include types EM, EEW, IPR, SMW, and SEW. Both types of batteries are shipped fully charged and filled with electrolyte, and also dry, without electrolyte. The following instructions cover the installation and preparation for service of these batteries.

Glass Jar Batteries. Fully Charged and Filled With Electrolyte

Each sixteen cell set of batteries is packed in two shipping crates.

One crate, which is stenciled "No. 1" contains:

* 8 Cells. * 18 Bolt Connectors. * 1 Hydrometer Syringe. * 1 Instruction Book.

The other crate which is stenciled "No. 2" contains: 8 Cells

(NOTE:--If the batteries are re-shipped by the manufacturer or distributor, care must be exercised to see that they are sent out in sets.)

Unpacking

Remove the boards from the tops of the shipping crates and the excelsior which is above the cells.

To straighten the long top connector, grasp the strap firmly with the left hand close to the pillar post and raise the outer end of the strap until it is in an upright position. Do not make a short bend near the pillar post. Lift the cells from the case by grasping the glass jars. Do not attempt to lift them by means of the top connectors.

Clean the outside of the cells by wiping with a damp cloth.

Inspection of Cells.

Inspect each cell to see if the level of the electrolyte is at the proper height. This is indicated on the jar by a line marked LIQUID LINE.

If the electrolyte is simply a little low and there is no evidence of any having been spilled (examine packing material for discoloration) add distilled or clean rain water to bring the level to the proper height.

If the liquid does not cover the plates and the packing material is discolored, it indicates that some or all of the electrolyte has been lost from the cell either on account of a cracked jar or overturning of the battery.

If only a small quantity of electrolyte is lost through spilling, the cell should be filled to the proper height with electrolyte of the same specific gravity as in the other cells. This cell should then be charged until the gravity has ceased rising. If all the electrolyte is lost write to the Willard Storage Battery Co., Cleveland, Ohio, for instructions.

Connecting the Cells

Each cell of the type PH battery is a complete unit, sealed in a glass jar. The cells are to be placed side by side on the battery rack so that the positive terminal of one cell (long connecting strap) can be connected to the negative terminal (short strap) of the adjacent cell.

Join the positive terminal of one cell to the negative terminal of the adjacent cell and continue this procedure until all the cells are connected together. This will leave one positive and one negative terminal of the battery to be connected respectively to the positive and negative wires from the switchboard. The bend in the top connector should be made about one inch above the pillar post to eliminate the danger of breakage at the post.

In tightening the bolts do not use excessive force, as there is liability of stripping the threads.

Give the battery a freshening charge before it is put in service. Type PH cells have a gravity of 1.250 when fully charged, and 1.185 when discharged.

Willard Glass Jar Batteries Shipped "Knock-Down."

Each sixteen cell set of Batteries consists of:

16 Glass Jars.
16 Positive Groups.
16 Negative Groups.
16 Covers.
16 Vent Plugs.
32 Lead Collars.
32 Lead Keys.
32 Soft Rubber Washers.
32 Hard Rubber Rods.
64 Hard Rubber Nuts.
18 Bolt Connectors.
Wood Insulators (the quantity depends upon the size of the cells).
Sealing Compound.
Hydrometer.
Instruction Books.

Electrolyte is not supplied with batteries shipped in a knockdown condition.

Examine all packing material carefully and check the parts with the above list.

Cleaning the Glass Jars

Wash the glass jars and wipe them dry.

Preparing the Covers

Wash the covers and scrub around the under edge to remove all dust. After they are thoroughly dry place them upside down on a bench.

Melt the sealing compound and pour it around the outer edge to make a fillet in the groove.

Assembling the Element and Separators

Place the plates of a positive group between the plates of a negative group and lay the element thus formed on its edge, as shown in Fig. 329.

[Fig. 329 Inserting Separators, Willard farm lighting cell]

[Fig. 330 and Fig. 331 Fastening cover to posts, Willard farm
lighting cell]

Next insert a wood separator between each of the positive and negative plates.

Next insert the hard rubber rods through the holes in the lugs of the end negative plates, and screw on the nuts. Do not screw the nuts so tight as to make the plates bulge out at the center. The rod should project the same amount on each side of the element.

Place the element in a vertical position.

The cover can now be placed over the posts. Slip a rubber washer and a lead collar over each post. The two key holes in the lead collar are unequal in size. The collar must be placed over the post so that the end which measures 3/16 inch from the bottom of the holes to the end of the collar will be next to the rubber washer. Dip the lead key in water and then put it through the holes, having the straight edge of the key on the bottom side. This operation can easily be done by using a pair of tongs (see Figs. 330 and 331) to compress the washer. After the keys are driven tight they can be cut off with a pair of end cutters and then smoothed with a file.

Sealing Element Assembly in Jar

[Fig. 332 Sealing Element Assembly, Willard farm lighting cell]

Turn the element upside down and place over a block of wood so that the weight is supported by the cover. (See Fig. 332.)

Heat the sealing compound by means of a flame (a blow torch will answer the purpose), and place the jar over the element, as shown in Fig. 331. The jar should be firmly pressed down into the compound. With a hot putty knife, clean off any compound which has oozed out of the joint. The assembled cell can now be turned to an upright position.

In case it is necessary to remove a cover, heat a wide putty knife and run it around the edge between the cover and the glass jar. This will soften the compound so that the cover can be pried off.

If it is necessary to remove the cover from the posts, the keys must be driven out by pounding on the small end, as the keys are tapered-and the holes in the lead collars are unequal in size.

Filling with Electrolyte

Fill the cells with 1.260 specific gravity electrolyte at 70° F. to the LIQUID LINE marked on the glass jars. (About I inch above the top edge of separators.) Allow the cells to stand 12 hours, and if the level of the electrolyte has lowered, add sufficient electrolyte to bring it to the proper height.

Initial Charge

Connect the positive terminal (long strap) of one cell to the negative terminal (short strap) of the adjacent cell and continue this procedure until all the cells are connected together. This will leave one positive and one negative terminal to be connected respectively to the positive and negative wires from the charging source.

The bends in the top terminal connectors should be made about one inch above the pillar posts to eliminate the danger of breakage at the post.

In tightening the bolts, do not use excessive force, as there is liability of stripping the threads.

After the cells have stood for 12 hours with electrolyte in the jars, they should be put on charge at the following rates:

Type Amperes ---- ------- PH-7 4 PH-9 5 PH-11 6-1/4 PH-13 7-1/2 PH-15 9 PH-17 10

They should be left on charge continuously until the specific gravity of the electrolyte reaches a maximum and remains constant for six hours. At this point, each cell should be gassing freely and the voltage should read about 2.45 volts per cell, with the above current flowing.

Under normal conditions it will require approximately 80 hours to complete the initial charge. The final gravity will be approximately 1.250. If the gravity is above this value, remove a little electrolyte and add the same amount of distilled water.

If the gravity is too low, remove a little of the electrolyte and add the same amount of 1.400 specific gravity acid and leave on charge as before.

After either water or acid has been added, charge the cells three hours longer in order to thoroughly mix the solution, and if at the end of that time the gravity is between 1.245 and 1.255, the cells are ready for service.

It is very important that the initial charge be continued until the specific gravity reaches a maximum value, regardless of the length of time required. The battery must not be discharged until the initial charge has been completed.

If it is impossible to charge the battery continuously, the charge can be stopped over night, but must be resumed the next day.

It is preferable to charge the battery at the ampere rate given above, but if this cannot be done, the temperature must be carefully watched so that it does not exceed 110° F.

Wilard Rubber Jar Batteries Shipped Completely Charged and Filled with Electrolyte

Immediately upon receipt of battery, remove the soft rubber nipples and unscrew the vent plugs.

The soft rubber nipples are to be discarded, as they are used only for protection during shipment. Inspect each cell to see whether the electrolyte is at the proper height.

If the electrolyte is simply a little low and there is no evidence of any having been spilled (examine packing material for discoloration), add distilled water to bring the level to the proper height.

If electrolyte does not cover the plates and the packing material is discolored, it indicates that some or all of the electrolyte has been lost from the cell, either on account of cracked jar or overturning of the battery.

If only a small quantity of electrolyte is lost through spilling, the cell should be filled to the proper height with electrolyte of the same specific gravity as in the other cells. This cell should then be charged until the gravity has ceased rising, If all the electrolyte is lost, write to the Willard Storage Battery Co., Cleveland, Ohio, for instructions.

Place batteries on rack and connect the positive terminal of one crate to the negative terminal of the next crate, using the jumpers furnished.

The main battery wires from the switch board should be soldered to the pigtail terminals, which can then be bolted to the battery terminals. Be sure to have the positive and negative battery terminals connected respectively to the positive and negative generator terminals of switchboard.

Before using the battery, it should be given a freshening charge at the rate given on page 510.

The specific gravity of the rubber jar batteries is 1.285-1.300 when fully charged, and 1.160 when discharged.

Willard Rubber Jar Batteries Shipped Dry (Export Batteries)

Batteries which have been prepared for export must be given the following treatment:

Upon receipt of battery by customer, the special soft rubber nipples, used on the batteries for shipping purposes only, should be removed and discarded.

Types SMW and SEW batteries should at once be filled to bottom of vent hole with 1.285 specific gravity electrolyte at 70° F.

In mixing electrolyte, the acid should be poured into the water and allowed to cool below 90° F. before being put into the cells. If electrolyte is shipped with the battery, it is of the proper gravity to put into the cells.

Immediately after the batteries are filled with electrolyte, they must be placed on charge at one half the normal charging rate given on page 510, and should be left on charge continuously until the specific gravity of the electrolyte stops rising. At this point, each cell should be gassing freely and the voltage should read at least 2.40 volts per cell with one-half the normal charging current flowing.

If during the charge the temperature of the electrolyte in any one cell exceeds 105° F., the current must be reduced until the temperature is below 90° F. This will necessitate a longer time to complete the charge, but must be strictly adhered to.

Under normal conditions it will require approximately 80 hours to complete the initial charge. The final gravity of the types SMW and SEW will be approximately 1.285. If the gravity is above this value, remove a little electrolyte and add same amount of distilled water while the battery is left charging (in order to thoroughly mix the solution), and after three hours, if the electrolyte is within the limits, the cell is ready for service. If the specific gravity is below these values, remove a little electrolyte and add same amount of 1.400 specific gravity electrolyte. Leave on charge as before. The acid should be poured into the water and allowed to cool below 90° P. before being used. The batteries are then ready for service.

Installing Counter Electromotive Force Cells

Counter EMF cells, if used with a battery, are installed in the same manner as regular cells. They are connected positive to negative, the same as regular cells, but the negative terminal of the CEMF group is to be connected to the negative terminal of the regular cell group. The positive terminal of the counter CEMF group is then to be connected to the switchboard.

[Image: Table of charge and discharge rates for different types
of batteries, Willard farm lighting batteries]

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Definitions and Descriptions of Terms and Parts -------------------------------

Acid. As used in this book refers to sulphuric acid (H2SO4), the active component of the electrolyte, or a mixture of sulphuric acid and water.

Active Material. The active portion of the battery plates; peroxide of lead on the positives and spongy metallic lead on the negatives.

Alloy. As used in battery practice, a homogeneous combination of lead and antimony.

Alternating Current. Electric current which does not flow in one direction only, like direct current, but rapidly reverses its direction or "alternates" in polarity so that it will not charge a battery.

Ampere. The unit of measure of the rate of flow of electric current.

Ampere Hour. The product resulting from multiplication of amperes flowing by time of flow in hours, e.g., a battery supplying 10 amperes for 8 hours gives 80 ampere hours. See note under "Volt?" for more complete explanation of current flow.

Battery. Two or more electrical cells, electrically connected so that combination furnishes current as a unit.

Battery Terminals. Devices attached to the positive post of one end cell and the negative of the other, by means of which the battery is connected to the car circuit.

Bridge (or Rib). Wedge-shaped vertical projection from bottom of rubber jar on which plates rest and by which they are supported.

Buckling. Warping or bending of the battery plates.

Burning. A term used to describe the operation of joining two pieces of lead by melting them at practically the same instant so they may run together as one continuous piece. Usually done with mixture of oxygen and hydrogen or acetylene gases, hydrogen and compressed air, or oxygen and illuminating gas.

Burning Strip. A convenient form of lead, in strips, for filling up the joint in making burned connections.

Cadmium. A metal used in about the shape of a pencil for obtaining voltage of positive or negative plates. It is dipped in the electrolyte but not allowed to come in contact with plates.

Capacity. The number of ampere hours a battery can supply at a given rate of current flow after being fully charged, e.g., a battery may be capable of supplying 10 amperes of current for 8 hours before it is exhausted. Its capacity is 80 ampere hours at the 8 hours rate of current flow. It is necessary to state the rate of flow, since same battery if discharged at 20 amperes would not last for 4 hours but for a shorter period, say 3 hours. Hence, its capacity at the 3 hour rate would be 3x2O=60 ampere hours.

Case. The containing box which holds the battery cells.

Cell. The battery unit, consisting of an element complete with electrolyte, in its jar with cover.

Charge. Passing direct current through a battery in the direction opposite to that of discharge, in order to put back the energy used on discharge.

Charge Rate. The proper rate of current to use in charging a battery from an outside source. It is expressed in amperes and varies for different sized cells.

Corrosion. The attack of metal parts by acid from the electrolyte; it is the result of lack of cleanliness.

Cover. The rubber cover which closes each individual cell; it is flanged for sealing compound to insure an effective seal.

Cycle. One charge and discharge.

Density. Specific gravity.

Developing. The first cycle or cycles of a new or rebuilt battery to bring about proper electrochemical conditions to give rated capacity.

Diffusion. Pertaining to movement of acid within the pores of plates. (See Equalization.)

Discharge. The flow of current from a battery through a circuit, opposite of "charge."

Dry. Term frequently applied to cell containing insufficient electrolyte. Also applied to certain conditions of shipment of batteries.

Electrolyte. The conducting fluid of electro-chemical devices; for lead-acid storage batteries it consists of about two parts of water to one of chemically pure sulphuric acid, by weight.

Element. Positive group, negative group and separators.

Equalization. The result of circulation and diffusion within the cell which accompanies charge and discharge. Difference in capacity at various rates is caused by the time required for this feature.

Equalizing. Term used to describe the making uniform of varying specific gravities in different cells of the same battery, by adding or removing water or electrolyte.

Evaporation. Loss of water from electrolyte from heat or charging.

Filling Plug. The plug which fits in and closes the orifice of the filling tube in the cell cover.

Finishing Rate. The current in amperes at which a battery may be charged for twenty-four hours or more. Also the charging rate used near the end of a charge when cells begin to gas.

Flooding. Overflowing through the filling tube.

Forming. Electro-chemical process of making pasted grid or other plate, types into storage battery plates. (Often confused with Developing.)

Foreign Material. Objectionable substances.

Freshening Charge. A charge given to a battery which has been standing idle, to keep it fully charged.

Gassing. The giving off of oxygen gas at positive plates and hydrogen at negatives, which begins when charge is something more than half completed-depending on the rate.

Generator System. An equipment including a generator for automatically recharging the battery, in contradistinction to a straight storage system where the battery has to be removed to be recharged.

Gravity. A contraction of the term "specific gravity," which means the density compared to water as a standard.

Grid. The metal framework of a plate, supporting the active material and provided with a lug for conducting the current and for attachment to the strap.

Group. A set of plates, either positive or negative, joined to a strap. Groups do not include separators.

Hold-Down. Device for keeping separators from floating or working up.

Hold-Down Clips. Brackets for the attachment of bolts for holding the battery securely in position on the car.

Hydrogen Flame. A very hot and clean flame of hydrogen gas and oxygen, acetylene, or compressed air used for making burned connections.

Hydrogen Generator. An apparatus for generating hydrogen gas for lead burning.

Hydrometer. An instrument for measuring the specific gravity of the electrolyte.

Hydrometer Syringe. A glass barrel enclosing a hydrometer and provided with a rubber bulb for drawing up electrolyte.

Jar. The hard rubber container holding the element and electrolyte.

Lead Burning. Making a joint by melting together the metal of the parts to be joined.

Lug. The extension from the top frame of each plate, connecting the plate to the strap.

Maximum Gravity. The highest specific gravity which the electrolyte will reach by continued charging, indicating that no acid remains in the plates.

Mud. (See Sediment.)

Negative. The terminal of a source of electrical energy as a cell, battery or generator through which current returns to complete circuit. Generally marked "Neg." or "-".

Ohm. The unit of electrical resistance. The smaller the wire conductor the greater is the resistance. Six hundred and sixty-five feet of No. 14 wire (size used in house lighting circuit) offers I ohm resistance to current flow.

Oil of Vitriol. Commercial name for concentrated sulphuric acid (1.835 specific gravity). This is never used in a battery and would quickly ruin it.

Over-Discharge. The carrying of discharge beyond proper cell voltage; shortens life if carried far enough and done frequently.

Paste. The mixture of lead oxide or spongy lead and other substances which is put into grids.

Plate. The combination of grid and paste properly "formed." Positive$ are reddish brown and negatives slate gray.

Polarity. An electrical condition. The positive terminal (or pole) of a cell or battery or electrical circuit is said to have positive polarity; the negative, negative polarity.

Positive. The terminal of a source of electrical energy as a cell, battery or generator from which the current flows. Generally marked "Pos." or "+".

Post. The portion of the strap extending through the cell cover, by means of which connection is made to the adjoining cell or to the car circuit.

Potential Difference. Abbreviated P. D. Found on test curves. Synonymous with voltage.

Rate. Number of amperes for charge or discharge. Also used to express time for either.

Rectifier. Apparatus for converting alternating current into direct current.

Resistance. Material (usually lamps or wire) of low conductivity inserted in a circuit to retard the flow of current. By varying the resistance, the amount of current can be regulated. Also the property of an electrical circuit whereby the flow of current is impeded. Resistance is measured in ohms. Analogous to the impediment offered by wall of a pipe to flow of water therein.

Rheostat. An electrical appliance used to raise or lower the resistance of a circuit and correspondingly to decrease or increase the current flowing.

Rib. (See Bridge.)

Ribbed. (See Separator.)

Reversal. Reversal of polarity of cell or battery, due to excessive discharge, or charging in the wrong direction.

Rubber Sheets. Thin, perforated hard rubber sheets used in combination with the wood separators in some types of batteries. They are placed between the grooved side of the wood separators and the positive plate.

Sealing. Making tight joints between jar and cover; usually with a black, thick, acid-proof compound.

Sediment. Loosened or worn out particles of active material fallen to the bottom of cells; frequently called "mud."

Sediment Space. That part of jar between bottom and top of bridge.

Separator. An insulator between plates of opposite polarity; usually of wood, rubber or combination of both. Separators are generally corrugated or ribbed to insure proper distance between plates and to avoid too great displacement of electrolyte.

Short Circuit. A metallic connection between the positive and negative plates within a cell. The plates may be in actual contact or material may lodge and bridge across. If the separators are in good condition, a short circuit is unlikely to occur.

Spacers. Wood strips used in some types to separate the cells in the case, and divided to provide a space for the tie bolts.

Specific Gravity. The density of the electrolyte compared to water as a standard. It indicates the strength and is measured by the hydrometer.

Spray. Fine particles of electrolyte carried up from the surface by gas bubbles. (See Gassing.)

Starting Rate. A specified current in amperes at which a discharged battery may be charged at the beginning of a charge. The starting rate is reduced to the finishing rate when the cells begin to gas. It is also reduced at any time during the charge if the temperature of the electrolyte rises to or above 110 deg. Fahrenheit.

Starvation. The result of giving insufficient charge in relation to the amount of discharge, resulting in poor service and injury to the battery.

Strap. The leaden casting to which the plates of a group are joined.

Sulphate. Common term for lead sulphate. (PbSO4.)

Sulphated. Term used to describe cells in an under-charged condition, from either over-discharging without corresponding long charges or from standing idle some time and being self discharged.

Sulphate Reading. A peculiarity of cell voltage when plates are considerably sulphated, where charging voltage shows abnormally high figures before dropping gradually to normal charging voltage.

Terminal. Part to which outside wires are connected.

Vent, Vent Plug or Vent-Cap. Hard or soft rubber part inserted in cover to retain atmospheric pressure within the cell, while preventing loss of electrolyte from spray. It allows gases formed in the cell to escape, prevents electrolyte from spilling, and keeps dirt out of the cell.

Volt. The commercial unit of pressure in an electric circuit. Voltage is measured by a voltmeter. Analogous to pressure or head of water flow through pipes. NOTE.--Just as increase of pressure causes more volume of water to flow through a given pipe so increase of voltage (by putting more cells in circuit) will cause more amperes of current to flow in same circuit. Decreasing size of pipes is increasing resistance and decreases flow of water, so also introduction of resistance in an electrical circuit decreases current flow with a given voltage or pressure.

Wall. Jar sides and ends.

Washing. Removal of sediment from cells after taking out elements; usually accompanied by rinsing of groups, replacement of wood separators and renewal of electrolyte.

Watt. The commercial unit of electrical power, and is the product of voltage of circuit by amperes flowing. One ampere flowing under pressure of one volt represents one watt of power.

Watt Hour. The unit of electrical work. It is the product of power expended by time of expenditure, e.g., 10 amperes flowing under 32 volts pressure for 8 hours gives 2560 watt hours.

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Index

A

Acetic acid from improperly treated separators 77 Acetylene and Compressed Air Lead-burning Outfit147 Acid Carboys 184 Acid. Handling and mixing 222 Acid. How lost while battery is on car 57 Acid. How to draw, from carboys 184 Acid should never be added to battery on car 57 Acid used instead of water 57 Active materials. Composition of 13 Active materials. Effect of quantity, porosity, and arrangement of, on capacity 42 Active materials. Resistance of 49 Age codes 242 Age of battery. Determining 242 Age of battery. Effect of, on capacity 47 Alcohol torch lead-burning outfit 148 Applying pastes to grids 11 Arc lead-burning outfit 148 Audion bulb for radio receiving sets 253

B

Battery box should be kept clean and dry 51 Battery carrier 173 Battery case (see Case). Battery steamer 158 Battery truck 173 Battery turntable 170 Bench charge 198 to 210 Bench charge. Arrangement of batteries for 200 Bench charge. Charging rates for 201 Bench charge. Conditions preventing batteries from charging 206 Bench charge. Conditions preventing gravity from rising 207 Bench charge. If battery becomes too hot 205 Bench charge. If battery will not hold a charge 208 Bench charge. If battery will not take half a charge 205 Bench charge. If current cannot be passed through battery 206 Bench charge. If electrolyte has a milky appearance 206 Bench charge. If gravity rises above 1.300 205 Bench charge. If gravity rises long before voltage does 205 Bench charge. If new battery will not charge 205 Bench charge. If one cell will not charge 205 Bench charge. If vinegar-like odor is detected 205 Bench charge. Leave vent-plugs in when charging 209 Bench charge. Level of electrolyte at end of 203 Bench charge. Painting case after 203 Bench charge. Specific gravity at end of 203 Bench charge. Specific gravity will not rise to 1.280 204 Bench charge. Suggestions for 209 Bench charge. Temperatures of batteries during 202 Bench charge. Time required for 203 Bench charge. Troubles arising during 204 Bench charge. Voltage at end of 203 Bench charge. When necessary 198 Bins for stock parts 158 Book-keeping records 302 (Omitted) "Bone-dry" batteries. Putting into service 229 Boxes for battery parts 183 Buckling 72 Buckling. Caused by charging at high rates 73 Buckling. Caused by continued operation in discharged condition 73 Buckling. Caused by defective grid alloy 73 Buckling. Caused by non-uniform current distribution 73 Buckling. Caused by overdischarge 73 Buckling does not necessarily cause trouble 73 Burning. (See Lead-Burning.) Burning-lead mould 164 Burning rack 162 Business methods 299 to 312 (Omitted)

C

Cadmium. What it is 176 Cadmium leads. Connection of, to voltmeter 179 Cadmium readings affected by improperly treated separators 181 Cadmium readings. Conditions necessary to obtain good negative-cadmium readings 210 Cadmium readings do not indicate capacity of a cell 175 Cadmium readings on short-circuited cells 180 Cadmium readings. Troubles shown by, on charge 206 Cadmium readings. When they should be taken 176 Cadmium test 174 Cadmium test. How made 175 Cadmium test on charging battery 181 Cadmium test on discharging battery 180 Cadmium test set. What it consists of 177 Cadmium test voltmeter 178 Calling for repair batteries 314 Capacity. Effect of age of battery on 47 and 89 Capacity. Effect of plate surface area on 42 Capacity. Effect of clogged separators on 88 Capacity. Effect of incorrect proportions of acid and acid in electrolyte on 88 Capacity. Effect of low level of electrolyte on 88 Capacity. Effect of operating conditions on 44 Capacity. Effect of quantity and strength of electrolyte on 42 Capacity. Effect of quantity, arrangement, and porosity of active materials on 42 Capacity. Effect of rate of discharge on 44 Capacity. Effect of reversal of plates on 89 Capacity. Effect of shedding on 88 Capacity. Effect of specific gravity on 43 Capacity. Effect of temperature on 46 Carbon-arc lead-burning outfit 148 Carboys 184 Care of battery on the car 51 to 68 Care of battery when not in service 67 Carrier for batteries 173 Case. Cleaning and painting, after repairs 372 Case manufacture 22 Case. Painting, after bench charge 203 Case. Repairing 360 Case. Troubles indicated by rotted 319 Case troubles 83 Cases. Equipment for work on 98 and 170 Casting plate grids 9 Cell connector mould 168 Cell connectors. Burning-on 213 Cell connectors. Equipment for work on 98 Cell connectors. How to remove 329 Changing pastes into active materials 12 Charge. (See Bench Charge.) Charge. Changes at negative plates during 30 and 39 Charge. Changes at positive plates during 30 and 40 Charge. Changes in acid density during 39 Charge. Changes in voltage during 38 Charge. Loss of, in an idle battery 89 Charge. Preliminary, in rebuilding batteries 349 Charge. Trickle 239 Charging bench133 to 139 Charging bench. Arrangement of batteries on 200 Charging bench. Temperature of batteries on 202 Charging bench. Working drawings of 134 to 139 Charging circuits. Drawings of 105 Charging connections. Making temporary 220 Charging. Constant potential 111 Charging equipment for farm lighting batteries 439 Charging equipment for starting batteries 100 Charging farm lighting batteries 455 Charging. Lamp-banks for 101 Charging. Motor-generators for 106 Charging rate. Adjusting 287 Charging rate. Checking 283 Charging rate. Governed by gassing 112 and 202 Charging rate. How and when to adjust 289 Charging rates for bench charge 112 and 201 Charging rates for new Exide batteries 226 Charging rates for new Philadelphia batteries 228 Charging rates for new Prest-O-Lite batteries 234 Charging rates on the car 283 Charging rebuilt batteries 373 Charging. Rheostats for 101 Chemical actions and electricity. Relations between 31 Chemical changes at the negatives during charge 30 Chemical changes at the positives during charge 30 Chemical changes at the negatives during discharge 29 Chemical changes at the positives during discharge 29 Chemical changes in the battery 27 to 31 Composition of jars 16 Composition of plate grids 9 Compound. Scraping, from covers and jars 334 Compressed air and hydrogen lead-burning outfit 147 Compressed air and illuminating gas lead-burning outfit 149 Condenser for making distilled water 160 Connections. Making temporary, for charging 220 Connectors. (See Cell Connectors.) Connector troubles 84 Constant-potential charging 111 Construction of plate grids 10 Convenient method of adding water 56 Corroded grids 77 Corroded grids. Caused by age 78 Corroded grids. Caused by high temperatures 78 Corroded grids. Caused by impurities 78 Corrosion 321 Covers. Eveready 17 Covers. Exide 19 and 21 Covers. Functions of 16 Covers. Gould 17 Covers. How to remove 331 Covers. Philadelphia diamond grid 16 Covers. Prest-O-Lite 18 and 19 Covers. Putting on the 365 Covers. Sealing 366 Covers. Single and double 16 Covers. Steaming 332 Covers. U.S.L. 18 and 20 Covers. Vesta 18 Covers. Westinghouse 417 Covers. Willard 19 Credit. Use and abuse of 301 (Omitted) Cutout. Checking action of 282? Cycling discharge tests 269

D

Dead cells. Causes of 87 Delco-Light batteries 466 Delco-Light batteries. Ampere-hour meter for 467 and 471 Delco-Light batteries. Burning-on new plates of 492 Delco-Light batteries. Burning-on new straps for 488 Delco-Light batteries. Care of cells of, in stock 493 Delco-Light batteries. Charging, after reassembling 481 Delco-Light batteries. Charging outside negatives of 484 Delco-Light batteries. Clearing high resistance shorts in 484 Delco-Light batteries. Clearing lug shorts in 484 Delco-Light batteries. Dis-assembling 474 Delco-Light batteries. Gauges and instruments for testing 466 Delco-Light batteries. General complaints from users of 495 Delco-Light batteries. Hydrometers for 468 Delco-Light batteries. Inspection trips 470 Delco-Light batteries. Pressing negatives of 485 Delco-Light batteries. Putting repaired cells into service 484 Delco-Light batteries. Re-assembling 477 Delco-Light batteries. Removing impurities from 483 Delco-Light batteries. Repairing broken posts of 487 Delco-Light batteries. Repairing lead parts of 486 Delco-Light batteries. Salvaging replaced cells of 486 Delco-Light batteries. Taking, out of commission 494 Delco-Light batteries. Treating broken cells of 482 Delco-Light batteries. Treating spilled cells of 482 Delco-Light batteries. Treating reversed cells of 483 Delco-Light batteries. Use of auxiliary straps with 492 Delco-Light batteries. When and how to charge 468 Discharge apparatus 270 Discharge. Changes at negative plates during 37 Discharge. Changes at positive plates during 37 Discharge. Changes in acid density during 35 Discharge. Chemical actions at negative plates during 29 Discharge. Chemical actions at positive plates during 29 Discharge. Effects of rates of, on capacity 44 Discharge. Voltage changes during 32 Discharge tests. Cycling 269 Discharge tests. Fifteen seconds 266 Discharge tests. Lighting ability 267 Discharge tests. Starting ability 267 Distilled water. Condenser for making 160 Dope electrolytes 59 and 199 Double covers. Sealing 366 Dry shipment of batteries 24 Dry storage 240 Dry storage batteries 265

E

Earthenware jars 184 Electrical system. Normal course of operation of 277 Electrical system. Testing the 276 Electrical system. Tests on, to be made by the repairman 279 Electrical system. Troubles in the 284 Electricity and chemical actions. Relation between 31 Electrolyte. Adjusting the 373 Electrolyte below tops of plates. Causes and results of 319 and 323 Electrolyte. Causes of milky appearance of 206 Electrolyte. Composition of 199 and 222 Electrolyte. Correct height of, above plates 55 Electrolyte. Effect of circulation of, on capacity 44 Electrolyte. Effect of low 67 Electrolyte. Effect of quantity and strength of, on capacity 42 Electrolyte. Freezing points of 67 Electrolyte. Leaking of, at top of cells 324 Electrolyte. Level of, at end of bench charge 203 Electrolyte. Resistance of 43 and 48 Electrolyte troubles. High gravity 85 Electrolyte troubles. High level 85 Electrolyte troubles. Low gravity 85 Electrolyte troubles. Low level 85 Electrolyte troubles. Milky appearance 85 Element. Tightening loose 363 Elements. Re-assembling 361 Equipment for discharge tests 270 Equipment for general work 98 Equipment for general work on connectors and terminals 98 Equipment for handling sealing compound 149 Equipment for lead-burning 97 Equipment for work on cases 98 and 170 Equipment needed in opening batteries 97 Equipment which is absolutely necessary 96 Eveready batteries. Claimed to be non-sulphating 401 Eveready batteries. Description of parts 404 Eveready batteries. Rebuilding 405 Examining and testing incoming batteries 317 Exide farm lighting batteries 466 to 498 Exide radio batteries 257 Exide starting batteries. Age code for 243 (Age code chart omitted) Exide starting batteries. Burning-on cell connectors of 382 Exide starting batteries. Capacities of 381 (Chart omitted) Exide starting batteries. Charging, after repairing 382 Exide starting batteries. Methods of holding jars of, in case 377 Exide starting batteries. Opening of 377 Exide starting batteries. Putting cells of, in case 382 Exide starting batteries. Putting jars of, in case 382 Exide starting batteries. Putting new, into service 225 Exide starting batteries. Re-assembling plates of 379 Exide starting batteries. Sealing single covers of 380 Exide starting batteries. Type numbers of 377 Exide starting batteries. Types of 375 Exide starting batteries. Work on plates, separators, jars, and cases of 379

F

Farm lighting batteries 435 to 510 Farm lighting batteries. Care of, in operation 453 Farm lighting batteries. Care of plant of, in operation 450 Farm lighting batteries. Charging 453? or (455) Farm lighting batteries. Charging equipment for 439 Farm lighting batteries. Determining condition of cells of 453 Farm lighting batteries. Difference between, and starting batteries 435 Farm lighting batteries. Discharge rules for 457 Farm lighting batteries. Exide 466 Farm lighting batteries. Initial charge of 448 Farm lighting batteries. Installation of plant 445 Farm lighting batteries. Instructing users of 449 Farm lighting batteries. Jars used in 436 Farm lighting batteries. Loads carried by 443 (Charts omitted) Farm lighting batteries. Location of plant 444 Farm lighting batteries. Overcharge of 455 Farm lighting batteries. Power consumed by appliances connected to 442 Farm lighting batteries. Prest-O-Lite 460 Farm lighting batteries. Selection of plant 440 Farm lighting batteries. Separators for 438 Farm lighting batteries. Size of plant required 442 Farm lighting batteries. Specific gravity of electrolyte of 438 Farm lighting batteries. Troubles with 458 Farm lighting batteries. When to charge 455 Farm lighting batteries. Wiring of plant for 444 Filling and testing service 291 Flames for lead-burning 211 Floor. Care of 188 Floor grating for shop 188 Floor of shop 186 Forming plates 11 Freezing points of electrolyte 67

G

Gassing causes shedding 74 Gassing. Charging rate governed by 112 and 202 Gassing. Definition of 31 Gassing. Excessive, causes milky appearance of electrolyte 86 Gassing of sulphated plates 40 and 75 Gassing on charge 37? and 202 Granulated negatives 78 Granulated negatives. Caused by age 78 Granulated negatives. Caused by heat 78 Gravity. (See Specific Gravity). Grids. Casting 9 Grids. Composition of 9 Grids. Corroded 77 Grids. Effect of age on 78 and 80 and 342? (344) Grids. Effect of defective grid alloy on 73 Grids. Effect of impurities on 77 and 78 and 80 and 342 Grids. Effect of overheating on 78 and 80 and 342? Grids. Resistance of 48 Grids. Trimming 10

H

Handling and mixing acid 222 Heating of negatives exposed to the air 78 High rate discharge testers 181 High rate discharge tests 266 and 267 and 374 Home-made batteries 25 Hydrogen and compressed air lead-burning outfit 147 Hydrogen and oxygen lead-burning outfit 146 Hydrometer. What it consists of 60 Hydrometer readings. Effect of temperature on 65 Hydrometer readings. How to take 61

I

Idle battery. Care of 67 Idle battery. How it becomes discharged 89 Idle battery. How it sulphates 70 Illuminating gas and compressed air lead-burning outfit 149 Impurities 76 Impurities which attack the plates 77 Impurities which cause self-discharge 76 Incoming batteries. Examining and testing 317 Incoming batteries. General inspection of 320 Incoming batteries. Operation tests on 320 Incoming batteries. When it is necessary to open 326 Incoming batteries. When it is necessary to remove from car 325 Incoming batteries. When it is unnecessary to open 325 Incoming batteries. When it is unnecessary to remove from car 324 Installing battery on the car 236 Internal resistance 48 to 50 Isolators 408 Inspection to determine height of electrolyte 55

J

Jars. Construction of 16 Jars. Filling with electrolyte 364 Jars for farm lighting batteries 436 Jars. Manufacture of 16 Jars. Materials used for 16 Jars. Removing defective 359 Jars. Testing, for leaks 356 Jars. Work on 356 Jar troubles caused by explosion in cell 83 Jar troubles caused by freezing 83 Jar troubles caused by improperly trimmed groups 83 Jar troubles caused by loose battery 82 Jar troubles caused by rough handling 82 Jar troubles caused by weights placed on top of battery 83

K

(No Entries)

L

Lead burning cell connectors 213 Lead burning. Classes of 211 Lead burning. Equipment for 97 and 143 Lead burning. General instructions for 210 to 220 Lead burning plates to straps 217 Lead burning terminals 213 Lead burning. Safety precautions for 213 Lead melting pots 220 Lead mould 164 Lead moulding instructions 220 Light for shop 187 and 190 Loose active material 75 Loose active material caused by buckling 76 Loose active material caused by overdischarge 75 Loss of capacity 88 Loss of charge in an idle battery 89 Lugs. Extending plate 219

M

Manufacture of batteries 9 to 26 Manufacture of batteries. Assembling and sealing 23 Manufacture of batteries. Auxiliary rubber separators 15 Manufacture of batteries. Cases 22 Manufacture of batteries. Casting the grid 9 Manufacture of batteries. Composition of the grid 9 Manufacture of batteries. Covers 16 Manufacture of batteries. Drying the pasted plates 12 Manufacture of batteries. Forming the plates 12 Manufacture of batteries. Home-made batteries 25 Manufacture of batteries. Jars 16 Manufacture of batteries. Materials used for separators 14 Manufacture of batteries. Mixing pastes 11 Manufacture of batteries. Paste formulas 11 Manufacture of batteries. Pasting plates 11 Manufacture of batteries. Philco slotted retainer 15 Manufacture of batteries. Post seal 16 Manufacture of batteries. Preparing batteries for dry shipment 24 Manufacture of batteries. Separators 14 Manufacture of batteries. Terminal connections 25 Manufacture of batteries. Treating separators 14 Manufacture of batteries. Trimming the grid 10 Manufacture of batteries. Vent plugs 22 Manufacture of batteries. Vesta impregnated mats 15 Mechanical rectifier 131 Melting pot for lead 220 Mercury-Arc rectifier 129 Milky electrolyte 206 Motor-generators 106 to 112 Motor-generators. Care of 110 Motor-generators. Operating charging circuits of 109 Motor-generators. Sizes for small and large shops 106 Motor-generators. Suggestions on 108 Moulding instructions 220 Moulding materials 220 Moulds. 164 to 170 Moulds for building up posts 165 Moulds for burning lead sticks 164 Moulds for cell connectors 168 Moulds for plate straps 167 and 169 Moulds for terminal screws 168

N

Negative plates. Changes at, during charge 39 Negative plates. Changes at, during discharge 37 Negatives. Bulged 79 Negatives. Granulated 78 Negatives. Heating of, when exposed to the air 78 Negatives with roughened surface 79 Negatives with softened active material 79 Negatives with hard active material 79 Negatives. Washing and pressing 351 New batteries. Putting, into service 224 Non-sulphating Eveready batteries 402

O

Open-circuits 86 Open-circuits. Caused by acid on soldered joints 86 Open-circuits. Caused by broken terminals 86 Open-circuits. Caused by poor lead burning 86 Opening batteries. Equipment needed in 97 Opening batteries. Heating sealing compound 332 Opening batteries. Instructions for 328 Opening batteries. Pulling elements out of jars 333 Opening batteries. Removing connectors and terminals 329 Opening batteries. Removing post-seal 331 Opening batteries. Scraping compound from covers 334 Opening batteries. When necessary 326 Opening batteries. When unnecessary 325 Operating conditions. Effect of, on capacity 44 Overdischarge causes sulphation 69 Oxides used for plate pastes 11 Oxygen and acetylene lead burning outfit 143 Oxygen and hydrogen lead burning outfit 146 Oxygen and illuminating gas lead burning outfit 146

P