Choosing your traction battery and charger

Traction batteries - general

Choosing your battery

Life factors

Chargers – general

Charging process - general

Oxyhydrogen gas – oxygen and hydrogen

Topping up

Water quality

Maintenance

Notes

1

Index ................................................................................................................ 1 Choosing your traction battery and charger ............................................... 2 Traction batteries - general .......................................................................... 3 Construction...................................................................................................... 3.1 Battery size ...................................................................................................... 3.1 A little battery chemistry .................................................................................. 3.2 Pause charging................................................................................................. 3.3 Self-discharge................................................................................................... 3.4 Cold stores ....................................................................................................... 3.4 Choosing your battery .................................................................................. 4 Standard battery ............................................................................................... 4.1 Acid circulation battery .................................................................................... 4.1 CSM (Copper Stretch Metal) battery ................................................................ 4.1 Construction of a CSM battery ......................................................................... 4.2 Dryfit battery, VRLA maintenance-free ........................................................... 4.3 Life factors ..................................................................................................... 5 How long does a battery last? .......................................................................... 5.1 Definition of a cycle ......................................................................................... 5.1 What affects the life of a battery?..................................................................... 5.2 Why is too much current used?........................................................................ 5.2 When does a battery sulphate?........................................................................ 5.2 Chargers - general ......................................................................................... 6 W charge characteristic .................................................................................... 6.1 I charge characteristic ...................................................................................... 6.1 Examples of constant current charging profiles ............................................. 6.2 Charging process - general .......................................................................... 7 Oxyhydrogen gas – oxygen and hydrogen.................................................. 8 Topping up ...................................................................................................... 9 Manually ........................................................................................................... 9.1 Automatically ................................................................................................... 9.2 Water quality .................................................................................................. 10 Maintenance .................................................................................................... 11 Daily ................................................................................................................. 11.1 Weekly ............................................................................................................. 11.2 Monthly ............................................................................................................. 11.2

2

Choosing your traction battery and charger The battery is the heart of your truck

A healthy heart means good quality of life. An unhealthy heart means poor quality of life.

Your doctor gives good advice when he says, “You should use your heart, but not abuse it.

You should load your heart, but not overload it.” Replace the word "heart" with the word

"battery" and you have some good advice from your battery supplier.

Without food and drink, even a genius can’t think

Good, sensible dietary habits prolong your life and allow you to be more active. The right

current in the right quantities prolongs the life of your battery and allows it to achieve optimal

performance throughout its life.

Therefore, you should always choose a battery that is big enough for the type of truck and

the work for which it is intended. Always use a charger that is correctly dimensioned and

gives the battery precisely the right, optimal charge.

Brains and brawn

– the right combination of charger and battery makes your life easier Size (capacity) should not be the only factor that influences your choice of a new battery. The type also plays a very important part in efficient operation and long life.

3. 1

Traction batteries - general Construction

A traction battery consists of a number of individual cells, each of 2 volts. For example, a 48-

volt battery consists of 24 cells connected in series, each with the same capacity (Ah). The

cells consist of brown positive filled tubes and grey negative lubricated plates that contain

various lead alloys (tubular plate batteries). Unlike starter batteries, which contain positive

plates, a truck battery consists of positive tubes. This is because a starter battery has to be

able to supply all its current for a short period of time to start a vehicle, while a traction

battery has to be able to supply its current over a longer period of time in order to be able to

last a full working day.

The electrolyte, which causes the electrical tension between the positive and the negative

terminals, consists of diluted sulphuric acid.

Example

A 48-volt/500-Ah battery consists of 24 cells connected

in series and enclosed in a painted or Levasint-coated

battery case, normally made of iron. Each cell is a 2-volt

cell and has a capacity of 500 Ah, which means that,

roughly speaking, the battery can supply 100 A non-

stop for 5 hours, equivalent to the nominal 5-hour

capacity. If, for example, 200 A is consumed per hour,

the battery can only operate for around 2 hours and not

2.5 hours, as you might think.

The faster a truck battery’s current is consumed, the lower its useful capacity.

Battery size

When a truck works, it consumes current from the

battery. The battery is emptied and must then be

recharged. We call this discharge and charge process

a battery cycle. The more current a piece of work

requires, the higher the battery capacity must be

unless its lifecycle (life) is reduced.

The truck’s battery compartment determines the

physical size of the battery. The larger the battery

compartment, the more capacity the truck battery can

have. The individual cells which make up the battery

are therefore produced in many different heights and widths. A large cell volume, which

means a lot of active material, produces a high battery capacity. GNB Industrial Power, for

example, has more than 150 different cell types in its standard range.

Above you can see a small selection of different traction cells that can be combined in the

thousands of different battery cases designed for all truck types produced worldwide.

3. 2

A little battery chemistry

In a new, charged lead/acid tubular plate battery, the plates are "clean", which means that

they have been cleaned of acid residue (sulphates), and the acid density is correct, normally

1.29 g/cm3, also expressed as 1290 g/l.

When the battery is being discharged, the lead plates use the free surrounding sulphuric

acid to send current out into the system. At the same time, some acid residue remains, the

so-called sulphates. The sulphates are deposited on the plates and reduce the area

available for the production of current, which finally stops altogether, and the battery is fully

discharged and sulphated.

Sulphates are

dissolved Density

increases

Sulphates are

dissolved

Plates

sulphateDensity

decreases

Plates

sulphate

Voltage increases Voltage decreases

ChargeDischarge

The plates in a discharged battery are therefore full of acid residue, and the acid density (g/l)

has decreased greatly on account of current production. When the battery is then charged,

the sulphates are broken down and the acid residue should combine with the very weak acid

in the battery.

However, the acid residue, which is much heavier than the surrounding liquid, falls to the

bottom and is therefore of no benefit to the cleaned plates. So the charger continues with a

gassing charge, whereby the current charged is mainly used only to agitate the acid in order

to move the heavy acid residue up in the cells and into contact with the somewhat more

dilute acid at the top of the battery. When the charger shows that it has finished, the plates

are clean and the acid is evenly distributed throughout the battery.

When a truck battery is in use, current production takes place where there is least resistance

and the distance to the surrounding acid is shortest, i.e. the distance from the surface of the

plates. As the surfaces sulphate, current production moves further and further into the plates

and finally it stops altogether. The battery is charged in the opposite order.

3. 3

Pause charging

If a partially discharged standard battery is pause charged, parts of the plates are cleaned

and are ready for use. But the clean plates do not have a very strong acid to work with as

the heavy acid residue has fallen to the bottom of the cells. This acid residue is not mixed

with the dilute acid until the gas point is reached and the gassing charge starts. Pause

charging is fine if the gas point is not

reached but the cleaned plates do not

work optimally until the acid has

reached its correct density again.

Therefore, if pause charging is

necessary, choose an acid circulation

battery, a CSM (Copper Stretch Metal)

battery or a charger with chemical acid

agitation.

When can you use pause charging?

Situations arise in which a battery does not have enough capacity for a full day's work. In

order to avoid discharging it more than 80%, it is necessary to use pause charging. The

discharge curves of three batteries are shown below. They can all meet the capacity

requirements for the day, but only one of them is handled correctly from the point of view of

the battery.

Fully

charged Gassing

Char-ging

80% 80% is the

correct depth of discharge

Deep

discharged

PausePause

All three batteries are fully charged at the start of the day and all three have two breaks

during the day. One of them is deep-discharged at the end of the day. This is the green one,

which was not pause charged. The red battery is pause charged during the first break of the

day, with the result that it gasses before it is disconnected from the charger, because more

is charged than is taken out.

The blue battery is only pause charged during the second break of the day, when the truck

driver is certain that the gas limit cannot be reached. Therefore, with a little care and the

correct charger, it can sometimes be useful to use pause charging.

3. 4

Self-discharge

In addition to its normal discharge, a traction battery also has a so-called self-discharge.

There is consumption in both the positive tubes and the negative plates, which just sulphate

on their own. On a daily basis, this is of no significance as the regular charges compensate

for this discharge. However, if the battery is stored for a period of time, it is clear that the

density will decrease. The self-discharge per month is approximately 5-7% of the battery’s

capacity but it depends greatly on the battery's age and the ambient temperature.

Consequently, it is recommended that a battery be stored in a cold, dry and frost-free room

- always fully charged.

Cold stores

When a truck battery is used in a cold environment, its capacity decreases, while the voltage

and the density increase.

This means that cold store batteries must be slightly bigger than normal and the charger and

battery indicator must be adjusted according to the actual average temperature. A normally

adjusted charger will not be able to charge a cold battery fully, which causes the battery to

be sulphated, meaning the capacity decreases further. A CSM battery with an intelligent

charger that can compensate for the temperature is best suited for cold operation.

The effect of the temperature on capacity

Acid temperature Battery capacity

+30°C 100%

+20°C 95%

+10°C 90%

0°C 80%

-10°C 70%

-20°C 50%

-30°C 35%

4. 1

Choosing your battery Standard battery

The standard lead/acid battery has not changed much since it first came into existence more

than 100 years ago. It is the type of battery used most throughout the world and it fully

meets the requirements made of a battery designed for normal operating conditions. If, in

compliance with the warranty, you use 80% of a battery’s capacity of around 5 operating

hours, the equivalent of a normal working day, a standard battery is the correct one to

choose. There is no reason to pay for a better or stronger battery if you do not need it.

Acid circulation battery

If there is not enough room in the truck for a battery that is big

enough for a full day’s work, or if you have less then around 8

hours available for charging, it is often a good idea to choose

an acid circulation battery. This is well suited for pause

charging and charging in as little as 6 hours. You just have to

be aware that, as the battery is too small for the job, it will be

exhausted before time. So its life will be somewhat shorter

than usual, depending on the level of over-consumption.

The advantage of a circulation battery’s “spot charges” is that

the heavy acid that normally falls to the bottom is agitated and

is immediately sent to the top as a result of the air supply

connected to the battery. This type of battery is more

expensive than a standard battery and it needs a special

charger with an air pump that must be purchased with the

battery in most cases. But the alternative would be to buy a

replacement battery.

CSM (Copper Stretch Metal) battery

Less internal resistance and high, stiff voltage make the CSM battery ideal for hard

operation and heavy lifting when you are really in a hurry. The faster current needs to be

consumed, the more suitable a CSM battery is. The resistance in a CSM battery’s negative

copper grids is 13 times lower than in traditional lead grids, which produces an energy gain

of up to 25%. So you get much more energy with the same capacity.

The idea behind the CSM battery

The idea behind the CSM battery is based on Ohm’s Law, which basically says that a

battery’s voltage loss is equal to current multiplied by internal resistance. The lower the

internal resistance, the lower the battery’s voltage loss (heat loss), which now becomes

useful energy instead, meaning a longer operating time.

4. 2

CSM batteries and pause charging

Due to the low internal resistance of a CSM battery, it supplies and collects current faster,

evenly distributed throughout the height and width of the cell. This means that the cell

voltage increases faster, with the result that the energy collected during pause charging is

higher than for a standard battery.

CSM technology was originally developed as a necessity for submarine batteries. Today it

has been patented by Exide Technologies.

The advantages of CSM batteries are obvious

Up to 25% more energy and thus a longer operating time than

standard batteries.

High constant voltage under hard operation compared with a

standard battery, which has a steadily decreasing voltage

throughout the course of operation. This decreasing voltage is

problematic for the truck’s electronics, which will react by

demanding more and more current.

Lower heat generation and thus less damage to the battery

throughout its life.

Construction of a CSM battery

1. Copper Stretch Metal grid 10. Patented terminal

2. Negative leaded CSM grid 11. Cell cover

3. Perforated protective casing 12. Flexible screw connection

4. Separator 13. BFS float

5. Negative lubricated grid plate 14. BFS plug

6. Positive lead grid 15. Seal cover

7. Positive tubular plate 16. Terminal screw

8. Negative plate assembly, Terminal 17. Gasket

9. Positive plate assembly, Terminal

4. 3

Dryfit battery – maintenance-free

Dryfit batteries are closed, valve-regulated (VRLA), maintenance-free traction batteries with

the same dimensions as standard batteries, but the difference is that they have slightly less

capacity per volume unit.

Moreover, these batteries can only be discharged to around 70%, whereas standard

batteries tolerate 80%. This means that the useful capacity of a given truck is much lower

than its nominal capacity. So before you choose a Dryfit battery, you must be completely

clear about the type of operation for which it will be used and you must know the daily

capacity consumption.

The advantages of dryfit

No topping up with water

Saves time and possibly money, as a lack of water shortens a battery’s life.

Lower energy consumption

More economical. Less current used for charging as the battery does not require an

agitation period.

No acid overflow

More economical. No acid in the battery case and on the floor and less cleaning of the

battery.

Virtually no gassing

Environmentally-friendly. Saves money. Smaller charging room and air extraction.

The disadvantages of dryfit

Lower discharge depth

Less economical as a larger battery is required than for open batteries.

Higher price

Less economical as dryfit batteries are generally around 50% more expensive than

standard batteries.

5. 1

Life factors How long does a battery last?

A battery's life depends entirely on how much it is used every day for however many days it

is used. So a battery's life varies from user to user.

A battery’s life in accordance

with the IEC 254-1 standard

5-6 years or 1500 cycles in normal

operation with one outlet and a

discharge depth of max. 80% per day.

The life of a dryfit battery is around 1200

cycles, but it may only be discharged to

0-75%.

finition of a cycle

7

De

a

,

d when

e next day's work begins.

discharge depth constitutes a deep discharge and invalidates the

attery warranty.

t for a full day’s work and you are certain that you will

ot reach the battery's gas limit.

A cycle is a discharge followed by

charge. The more cycles a battery

undergoes in a 24-hour period, the

shorter its life in terms of time. The best rhythm for a battery is one cycle every 24 hours

which means that the battery must be charged when the day’s work is done and when it has

been discharged to max. 80% (dryfit: 70-75%) of its capacity, so that it is fully charge

th

Over 80% (70-75%)

b

In principle, pause charging, i.e. an incomplete charge of a partially discharged battery, is a

permissible option but it also risks the temperature becoming too high or the gas limit being

reached (this counts as 1 cycle). For this reason, pause charging should only be considered

if the battery capacity is not sufficien

n

5. 2

The chart shows the number of cycles aNumber of

cycles battery contains throughout its life atvarious discharge depths.

Discharge depth and life:

80% discharge produces 100% life.

90% discharge produces roughly 75% life.

1500

hat affects the life of a batter

Discharge depth in% 60% 70% 80% 90%

W y?

eep discharges:

t, faults, etc.

hy is too much current used?

D Max. 80% depth

Over-consumption: Max. 80% of capa city

High temperatures: Max. 50°C in the acid

Overcharging: Burns the battery out

Undercharging: Sulphates the battery

Maintenance: Incorrect acid level, dir

W

attery too small

at the same time

els)

driving surface

hen does a battery sulphate?

B

Driving and lifting

The truck driver thinks he’s a “racing driver”

Truck fault (wear, brakes sticking, dirt in whe

Too much additional equipment

Incorrect tyre type, ramp driving,

W

it is left uncharged

to 80% every now and again, it gets “sluggish”

erature

he above points are the main reasons why a battery does not last as long as expected.

a

your battery’s life.

If

If it is not discharged

If it is not fully charged

If it works at a high temp

If it is topped up with acid

T

Some of the factors destroy the battery very quickly. Others take slightly longer. However,

common feature of them all is that they can be avoided if you are interested in prolonging

6. 1

As it is the battery that keeps the truck going, users often only focus on the battery, ignoring

the charger, which is usually regarded as just an expensive but necessary evil.

The charger supplies the battery with “fuel”, which, in turn, supplies the truck with energy,

just like petrol in a car engine, and who would put 92 Octane fuel in a 98 Octane engine?

Incorrectly charging a battery will simply destroy the battery bit by bit, or possibly even very

quickly.

So it is very important to be quite clear what performance you require of your battery pack

now and in the future. Hard operation or normal operation? How much time do you have

available for charging? Do you work for a few hours a day or around the clock? These

questions should be answered before you buy a charger.

Chargers - general

6. 2

Two types of charger are available today, “W”

constant-effect-chargers and “I” constant-Charging process

current- chargers.

W charge characteristic

A constant-effect-charger generally produces

the same effect (W) throughout the charging

process, which produces a decreasing current

characteristic. This means that, as the battery

voltage increases, the current decreases until

the voltage reaches the gas limit of roughly 2.4

volts per cell (V/c), at which point water begins

to divide into oxygen and hydrogen.

The current then decreases to roughly 25% of the charger’s rated current value, after which

it stabilises until the charging has been completed. This phase is called the gas phase.

When the battery is fully charged, the charger stops. Most chargers will then start a

maintenance charge which may be either constant current or current pulses that maintain

the battery’s voltage level.

I charge characteristic

A constant-current-charger produces the

charger’s rated current throughout the bulk

charging process until the gas limit of roughly

2.4 V/c has been reached. The charge

with constant voltage of 2.4 V/c until the

current is so low that the actual gas phase

ne of the many advantages of constant-current-chargers is that the battery is generally

fully charged when the gas point is reached. This means that the charging time is greatly

reduced. These chargers are also based on the microprocessor principle, which means that

the charging process is read off continuously and the charging is adjusted in line with the

readings. The latest of these chargers are high-frequency (HF) chargers, which cause the

battery the least damage.

Charging process

W-characteristic

IUI-characteristic

characteristic varies somewhat after this,

depending on battery type.

In the graph to the left, the charger continues

can start.

O

6. 3

Examples of constant-current-charge curves

2100 HFP hig n tubula te batteries

- IWa charging profile

Constant current until the battery is almost ch rrent until the

voltage has become constant for a given peri d of time. 10 min. maintenance charging every

6 hours.

2100 HFP high dryfit tubular plate batteries

- IUIU charging profile

Constant current until the voltage reaches 2.3

has decreased to 10% of the nominal value. T fully

charged. Constant maintenance charging so V/c.

he above are just two examples of charging profiles for an open battery and a closed

battery. However, the battery suppliers’ prescribed curves may be different so it is a good

idea to check the profile for any existing charger if it is subsequently connected to a new

battery.

h-frequency for ope r pla

arged. Then decreasing cu

o

-frequency for closed

5 V/c. Then constant voltage until the current

hen constant current until the battery is

that the cell voltage does not fall below 2.3

T

7

neral Charging process - ge Bulk charge

ly

ffect-charger during this phase.

Gassing charge

The charging time is from when the charger is started until the gas point at approximate

2.4 Volts per cell is reached. A constant-current-charger charges up to 20% more than a

standard e

The charging time from when the gas point is reached until the charge is finished varies from

charger to charger. Some gas phase times are a percentage of the main charge time and

others are controlled by the microprocessor's program.

Maintenance charge

When the battery has been fully charged, most chargers continue with some form of

maintenance charging to counteract the battery's self-discharge.

qualising charge

E

ammed to continue charging with a weak current for a number of

ours in order to adjust any cells that have too low voltage.

Always remember to switch the charger off or press the pause button each time the battery is disconnected from or connected to the charger

If the charging connectors are disconnected live, sparking may occur.

Some chargers are progr

h

8

Oxyhydrogen gas – oxygen and hydrogen

s disconnected from the charger before the charging process is finished will

sually emit gas. A battery that is fully charged with the cover closed will take a long time to

battery that explodes will most probably burst the cell covers and expel acid out into the

urrounding area. If there is anyone nearby, they will be hit by the acid.

the event of an accident, the acid can be adequately neutralised with plenty of running

Avoid cigarettes, sparks and open flames near the

Your eyes are most at risk, so you should always use protective goggles. There

A battery that i

u

emit its gases. This means that the air around the battery is full of hydrogen gases that

explode on contact with the slightest spark.

A

s

In

water, followed by an immediate visit to a hospital accident and emergency department.

NB!

battery

must be an eyewash bottle near the charger.

9. 1

“die” very quickly. To avoid this, it is necessary

top up with water occasionally, but only with demineralised water.

Topping up When a battery gases, water disappears and not acid.

This means that the acid concentration increases in the remaining liquid and the plates are

no longer covered. This causes the battery to

to

Water can be added in many different ways, for example:

Manually

A simple water bag with a hose and a

gate valve.

A watering can with a standard spout.

A watering can with a self-stopping

il” with a filling

ut never use equipment in which the

ater can come into contact with metal

s otherwise it will immediately

nised.

AccuPub with LED filling gun

spout.

An inflatable “HandyF

tube and manual water cock.

B

w

a be

io

Still manual, but the easiest method on the

ts of a filling

r out through an

ch cell reaches the

gun

ater supply.

pacers, the AccuPub can be

used for all cell types.

No overflow of water or destructive acid.

Always uniform, equal acid level in all cells

after each top-up.

Stops topping up itself when the cell is full.

No extra accessories or equipment on the

batteries.

Can be used for all makes of battery by

just replacing the spacer.

market. The AccuPub consis

trolley that pumps the wate

optical filling gun. When ea

correct liquid level, the filling

automatically shuts off the w

Using various s

9. 2

Automatically

anual topping up is time-consuming. Therefore, several different automatic systems are

vailable today that can make life easier for the people who look after batteries on a daily

hoses that are connected to a

entral, mobile or permanently installed water supply. Automatic topping-up plugs shut off

ating plugs that are connected to each other via plastic

entire system ends in a quick-acting coupling that must be connected to a

uitable water supply. The three known systems available on the market today work in

different ways. However, the principle of the p gs and the hose connection is a common

feature.

The BFS system

M

a

basis. Automatic topping up takes place via cell plugs on

c

the water when the cells are full.

All cells in the battery have level-regul

hoses. The

s

lu

The BFS system is the most widely used syst

a high place which can provide a pressure of

pply

on is a standard 25-

of

u are advised to

use a mobile water trolley.

Th 4 cells with the BFS- system mounted

Indicator cylinder

Valve cylinder

Water cylinder

Gassing cylinder

T cylinder for water connection

e picture shows

The picture shows the structure of a BFS plug

em. A BFS water trolley or a water container in

between 0.3 and 2 bar (min. 3 m height) is

required as the water su

source.

If you only have a few

batteries, the simplest

soluti

litre water container with a

hose and a quick-acting

coupling.

If you need to top up a lot

batteries, yo

9. 3

ystem The Aqua Jet s

tank are also

quired.

When the topping-up tank is full and pressurised,

the hose system is connected to it and the battery

is ready for use in less than 30 seconds.

The Aqua-Jet system is the fastest topping-up

system on the market and works at high pressure.

The battery cells are connected by hoses in this

system. An external water supply and a pump that

can create the right pressure in the

re

The Autofil system

he Autofil system also has the battery cells

onnected by hoses, and has an external topping-

p trolley or a wall-mounted box that to

attery using negative pressure, unlike the other

The following applies to all systems:

Only top up with demineralised water.

T

c

u ps up the

b

systems.

The Autofil system, which used to be very popular,

is in the process of disappearing from the market.

10

ity Water qual mS - microSiemens

d water is at 0-5 mS. However, if it is placed in clear containers, its mS value

ill gradually increase so much that it cannot be used for batteries. This is because of the

sable to use coloured containers or dark

eriod of time.

the water comes into contact with metal, for example taps, pipes or topping-up heads, the

ater’s value increases to 50-60 mS, which is unacceptable. The water should preferably

ot exceed 10 mS and must never exceed 20 mS.

you have a lot of batteries and use a lot of water, it may be worth buying your own

emineralisation system.

Normal tap water is usually around 250 microSiemens.

Demineralise

w

liberation of salts by bacteria. As a result, it is advi

rooms if the water is to be stored for an extended p

If

w

n

If

d

11. 1

Maintenance Prevention is better than cure

Make sure at all times that your battery is "in good health". Visible defects and deficiencies

ust be remedied immediately to avoid subsequent high repair costs which could easily

ded by spending a few

inutes a day on the battery.

addition to the battery care mentioned above, there are a few things that must be done

charger arging

t must

er or e button.

y and close the

ttery connector

m

have been avoided. A defective cable will result in unnecessarily high current. Dirty, damp

cell covers will result in leak current and drain current from the battery. Acid overflow will

reduce the battery's capacity and break down the battery case. Too little liquid in the cells

will sulphate and damage the battery. All of the above can be avoi

m

If you check your battery and remedy any faults in time, you will prolong its life.

In

every day, every week and every month.

M

Check that the has finished chthe battery.

The green lighbe on.

Switch off the chargpress the paus

Wipe the batterbattery cover.

Connect the bato the truck and drive off.

orning

When you start work –

Daily Evening

– When you stop work

Drive the truck close enough to the charger that the battery connector and the charger connector can easily reach each other.

Turn the ignition key and switch off the current.

Open the battery cover so that the gases can escape during charging.

Connect the charger connector to the battery connector.

Switch on the charger if it has a switch.

Check that the charger starts before leaving it. The red light must be on. Some chargers have a yellow light.

d the charger

cables.

Disconnect the batteryconnector anconnector.

Do not pull the

11. 2

Maintenance

Check (every Friday, for instance) that the acid level is above the fore charging the battery. If the acid th demineralised water so that the

is too low, top it up with etres

the cells, time the battery is charged.

s, cable terminals and connectors. d immediately. Ensure that the cell he battery wit nd hot

rrect level after charging has

perature in the centre cell e battery is fully charged and idle. The temperature must not

ly be around 30°C. Then measure lls and note the maximum and

ween tdergo an equalisin

g on the age of the battery. The tionship between density and se as the temperature decreases.

Weekly

Monthly

lead plates and separators belevel is too low, top it up wi

ttery is idle. If the acid level

they will “boil over” the next

Check the cell connectionAny defects must be remedieplugs are closed. Then wash twater and wipe it dry. Use protective goggles.

Top up with water to the cofinished.

acid just covers the plates but is no higher. If you charge a battery with an acid level that is too high, the acid will overflow down into the battery case. If this happens too frequently, the battery will require acid adjustment. If you charge a battery with exposed plates, the battery will gradually be ruined. Then check the acid level mid-week after charging when the bademineralised battery water until the acid is 1-2 centimabove the plates. If you pour too much water into

Always use approved demineralised battery water.

h a brush a

NB!

Measure the temth

of the battery when

exceed 50°C but will normalthe density or voltage in the ceminimum values. If the difference betgreat, the battery must un

pendin below shows the rela

ncreainal value.

hese values is too g charge to

equalise the cells, detablevoltage. The values i30°C is the nom

Temp. Density Volt

0°C 1.31 2.15

15°C 1.30 2.14

30°C 1.29 2.13

45°C 1.28 2.12