PART II

RULES OF PROPER USAGE

AND

BATTERY MAINTANANCE

Base hold downs

Terminals ( meltings, mechanical defects )

Container mechanical damage

Electrolyte effluent

GENERAL EVALUATION OF BATTERY CONDITION

Charge level indicator condition:

green – battery charged

black – battery discharged ( charge it! )

white – low level of electrolyte

EVALUATION OF CHARGING STATE

EVALUATION OF CHARGING STATE

• Evaluation of electrolyte density

• 1,27g/cm3 ÷1,30 g/cm3 - completly charged• 1,22g/cm3 ÷1,25 g/cm3 - partly charged (charge it! )• below 1,20 g/cm3 – discharged ( for immidiate charging )

• Evaluation of ELECTROMOTIVE FORCE

• ELECTROMOTIVE FORCE should be: - 12,60V ÷ 12,90V ( for 12V batteries) - 6,30V ÷ 6,45V ( for 6V batteries)

• Evaluation of voltage under short-time load

• To be ilustrated later on

CHARGING RATIO DEPENDING ON ELECTROLYTE DENSITY BY + 25 °C

20 HOUR CAPACITY Q20 DEPENDING ON ELECTROLYTE TEMPERATURECOMPLETLY CHARGED BATTERYDensity [g/cm3] 1,05 1,10 1,15 1,20 1,25

Temperature [°C] -5 -9 -15 -27 -60

Very low electrolyte density and low temperature could cause freezing of electrolyte and braking the battery container.In discharged battery electrolyte density goes down close to water state.

Dangerous density around 1,11÷1,13 [g/cm3]

Correction of electrolyte density Correction of electrolyte density ddepending on the temperatureepending on the temperature

Example 1

TEMPERATURE : 25 ºCDENSITY : 1,250Electrolyte Temperature: -5 ºCREDUCTION : 0,024 POINTSREVISED DENSITY : 1,226

Example 2

TEMPERATURE 25 ºCDENSITY : 1,235Electrolyte Temperature : 35 ºCADDITION : 0,008 POINTSREVISED DENSITY : 1,243

SYSTEM 6V – ( 6,9 ÷ 7,2 )V

SYSTEM 12V – ( 13,9 ÷ 14,4 )V

SYSTEM 24V – ( 28 ÷ 28,8 )V

VEHICLE CHARGING VOLTAGE

1.Keep the battery in charged state

Discharged battery left may cause sulfate of plates and fast damage.

2.Avoid electrolite freez-up

Due to low temperature the electrolyte may get freezed (low electrolyte density) what results in a permanent damage of a battery (plates degradation)

RULES OF PROPER BATTERY USAGE

• 3. Keep poles and surface of a battery clean

• Dirty, corroded poles and may cause sparking, which might result in a battery explosion.

• Dirt on a surface may speed up a self-discharge and worsen electrical parameters of a battery.

• 4. Never allow to deep self discharge of a battery.

• 5. Level of electrolyte refill with destilled water, not with acid.

• 6. Metal pieces of a battery cover with a thin layer of vaseline.

RULES OF PROPER BATTERY USAGE

CUSTOMER COMPLAINT SOLVING AND ESTIMATING A CONDITON OF A BATTERY

1. FIRST STEP – check the formal data:

Guarantee certificate Date of purchase by a client

2. SECOND STEP - Visual inspection:

Box and lid (mechanical damages, leaks) Corks (mechanical damages)Poles (mechanical damages)

3. THIRD STEP - Inspection of electrical parameters of a battery:

SEM – in a fully charge battery should be between 12,6-12,9V (for 12V batteries) and 6,30-6,45V (for 6V batteries) Voltage under short-time load (see printed attachement)Electrolyte density:

- 1,27g/cm3 ÷1,30 g/cm3 - fully charged- 1,22g/cm3 ÷1,25 g/cm3 - partly charged - below 1,20 g/cm3 – discharged

Customer complaint solving procedureA . VISUAL INSPECTION

1. ANY LEAKS?

YES – go to A-2

NO – go to B

2. ARE THERE ANY MECHANICAL DAMAGES CLOSE TO THE LEAK(S)?.

YES – refuse a complaint

NO – admit a complaint

3. IS THE LEVEL OF ACID EVEN?Yes – go to B

NO– refuse a complait (battery overcharged)

Properly working battery should have the same density inall cells. The density should be between (1,27 ÷1,30) g/cm3 in 25°C

If acid density is lower then 1,25 g/cm3 thebattery must be charged prior to electrical inspections

Acid density in 25ºC (g/cm3) Condition of a battery Recommended procedure

1,27 ÷ 1,30 Charged Continue with inspection

1,20 ÷ 1,25 Partly charged Charge the battery

below 1,20 Discharged Charge the battery immediately

Attention: 100% discharge may be a reason for a complait refusal

1. Density in one cell lowerYES – adimit a complait

NO – go to B2

2. Is there a change in the color of electrolyte (dark brown, black), are there sings of electrolyte evaporation?

YES - refuse a complait, damage caused by overcharging (check voltage in car electric system)

NO – go to B4

B ELECTROLYTE DENSITY INPECTION

3. If electrolyte density is lower then 1,25 g/cm in all cells charge the battery. Is a density higher after recharge?

YES – go to C

NO – battery worn out,reject a complaint

C HIGH CURRENT LOAD INSPECTION e.g. tester A 600

The examination should be done when the battery is fully charged. The voltage afterhigh current load inspection should be compared with the results from the attachedtable. If the results of tests are the same or better it means that the battery works properly,in the opposite case the complait should be admitted.

Areometer with a pipette with a range 1,15 ÷ 1,30g/cm3

Direct current voltmeter to 30V, precission class better then 1

Tester for high current load inspection – we advice A-600 produced by LEWANDA

Ammeter for possible check of current consumption of a car starter and for detection of short cuircut in car electric system.

MEASURING INSTRUMENTS NECESSARY FORPROPER BATTERY CONDITION ESTIMATION

Electric requirements for technical efficiency

Estimation of lead-acid starter batteries used in a guarantee period

information based on the results of tests done by ZAP SZNAJDER BATTERIEN S.A

Inspection of lead-acid batteries in a guarantee period

Voltage CapacityDischarge current intensity

by the high current load examinationMinimal voltage by the high

current load examination

U C20 150 200 255 300 400 450 600 UV Ah A A A A A A A V12 30 - 40 X 9,5

12 30 - 40 X 9,0

12 41 - 50 X 9,6

12 41 - 50 X 9,1

12 50 X 8,7

12 51 - 60 X 9,7

12 51 - 60 X 9,3

12 51 - 60 X 8,7

12 60 X 8,7

12 61 - 90 X 9,1

12 61 - 90 X 8,6

12 91 - 130 X 8,9

12 91 - 130 X 8,2

12 131 - 170 X 9,4

12 131 - 170 X 8,8

12 171 - 210 X 9,5

12 171 - 210 X 9,0

6 165 - 195 X 5,2

6 165 - 195 X 5,0

6 165 - 195 X 4,6

6 165 - 195 X 4,3

Discharge current intensities and voltages given above are for tests which last no longer then 5 s.

SAFETY RULES BY WORKING WITH LEAD-ACID BATTERIES

By working with batteries you should wear:

- Acidproof dress- Rubber shoes/boots- Safety glasses- Gloves- Head coverage

During battery charging don’t use any sparking devices, avoid open fire and glowing objects.

- Avoid skin and eye contact with acid

SAFETY RULES BY WORKING WITH LEAD-ACID BATTERIES

In case of contact of acid with the skin immediately flush with running water.

Spilled electrolyte neutralize with sodium carbonate

Battery should be charged in a special room with efficient ventilation.

Used batteries should be stored in special containers, which guarantee that they are out of contact of other people.

In Poland used batteries are sent to lead smelting plant for recycling.

THANK YOU

FOR YOUR ATTENTION