[Fig. 332 Sealing Element a.s.sembly, 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 a.s.sembled 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 gla.s.s 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 gla.s.s 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 ga.s.sing 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 quant.i.ty 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 ga.s.sing 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]