Electrical Systems
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NOTE: See chart for temperature compensation. Liquid levels should
be even between the cells of the battery being tested as it will affect
the accuracy of the test.
WARNING: Sulfuric acid in the batteries can cause severe injury or
death. Sulfuric acid can cause permanent damage to eyes, burn skin
and eat holes in clothing. Always wear splash-proof safety goggles
when working around the battery. If battery electrolyte is splashed in
eyes or on skin, immediately flush the affected area for 15 minutes
with large quantities of clean water. In case of eye contact, seek
immediate medical aid. Never add acid to a battery once the battery
has been placed in service. Doing so may result in hazardous
splattering of electrolyte.
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1. Physical Condition:
Active material flakes off the plates and falls to the bottom of the cell.
This is normal, but sediment accumulates under the plates and can short out a
cell. The plate separators fail to insulate positive and negative plates in a cell
and the cell becomes shorted, ruining the battery.
2. Insufficient Electrolyte:
This allows exposed portions of the plates to sulfate rapidly. This reduces
the battery’s ability to accept a charge, and the battery capacity is reduced.
Accelerated erosion of the lower portions of the plates occur from higher than
normal acid content due to water loss. Only the water evaporates, not the acid.
The battery also has a higher internal resistance when low on water. Add only
distilled water. Fill each cell to the bottom of the vent well when the battery is
warm. Filling a very cold battery with water to the bottom of the vent well will
cause overspill when the battery warms up and the plates expand. A Battery
Formula For Failure: the battery has a higher internal resistance when low on
water, therefore: high resistance = more heat = shorter battery life!
3. Sulfation:
When a battery is allowed to remain discharged too long the accumulated
lead sulfate in the plate material solidifies and cannot reenter the electrolyte.
Sulfate in plates is not able to reconstitute the electrolyte to a higher specific
gravity, or to restore the plate material to a more active composition.
4. Overheating:
A battery operated, when the electrolyte temperature reaches 125º F,
increases the chemical reaction. This increases the corrosion of the plates and
reduces the battery life. When overheated, the battery plates tend to buckle and
destroy the structural integrity of the battery.
5•153
EXECUTIVE
Seven Reasons
Why Batteries Fail
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