Download ALL YOU NEED TO KNOW

ALL YOU NEED TO KNOW
CONTENTS
1 STORAGE
2 MAINTENANCE OF STOCK
3 COMMISSIONING
4 ELECTROLYTE LEVELS (ACID LEVELS) IN SERVICE
5 SELECTING THE CORRECT BATTERY FOR THE APPLICATION
6 REMOVING BATTERIES & INSTALLING BATTERIES ON VEHICLES
B
BEFOREIHANDLING, CHARGING OR
INSTALLING
U BATTERIES, PLEASE UNDERSTAND
AND COMPLY
WITH THE PRECAUTIONS GIVEN
T
IN HEALTH
&
SAFETY
INFORMATION' IN THIS
'
CATALOGUE.
7 CHARGING OFF-VEHICLE
8 CHECKING BATTERY PERFORMANCE
9 MAINTENANCE IN SERVICE
1. STORAGE
a1. STORAGE
Practice first in, first out.
B
a) Always
rotate your stock. Practice first in, first out.
r
Batteries
slowly lose their charge, and good stockB
m
b rotation stops batteries going flat in storage, and
battery.
c makes sure that the customer buys a good
(Heat
causes
b) Store
batteries
in
a
cool,
dry
well
ventilated
area.
b
c) Protect
batteries from excessive heat. (Heat causes
e
batteries to lose their charge more quickly, and
d b
e
fexcessive heat can damage batteries).
d)
Store
batteries in an upright position to prevent them
e
falling over or leaking.
a
e) Do
t not stack batteries on top of other batteries to
f avoid scratching, tearing labels and damaging
that stand proud of the lid.
tterminals
S
f) Store
batteries on racks or on pallets - not on the floor.
d
g Small stones or sharp points on a concrete floor can
damage the base of the battery and cause leakage.
d
U
g) Make sure handles are left flat (in the down position).
g
Upright handles are more likely to be damaged.
2. MAINTENANCE
OFOF
STOCK
2. MAINTENANCE
STOCK
W
a
WET
s BATTERIES
a) Check
the open-circuit
of the
batteries
m
If you havevoltage
a voltage
below
12.50Vin your
stock
every month using a digital voltmeter or a
(
(multimeter. If you have a voltage below 12.50V
((6.25V for 6V batteries), give them a refreshing charge.
(See Section 7).
b) Scrap any batteries that drop below 11.00V - these
batteries will have developed a sulphation that cannot
be completely reversed by charging, and so will not
give the expected performance and life to the customer.
DRY
D
r CHARGED BATTERIES
a)
a If you keep the batteries cool and dry and do not
rremove the seal, dry charged batteries do not need
any other attention.
a
b)
b The maximum storage time of dry charged batteries
before
they are commissioned by filling with acid is
b
24 months.
2
3. COMMISSIONING
3. COMMISSIONING
WET BATTERIES
W
a)
a Do not supply a battery to a customer (end user) if the
voltage
is below 12.50V (6.25V for 6V batteries).
v
Charge
any batteries with voltages below these values.
C
b)
b We recommend you check the condition of the battery
before selling it.
b
DRY
CHARGED BATTERIES
D
a)
a Only commission a dry charged battery when it is
needed
for a customer.
n
b) If fitted, remove and discard any sealing plugs, tape
or foil.
c) If fitted remove and keep normal vent plugs and
terminal covers (usually red and black).
c) If
fitted
remove
keepgrade
normal
ventsulphuric
plugs and
d)
For
filling,
use aand
battery
dilute
acid of
terminal
covers
(usually
red
and
black).
specific gravity 1.270 - 1.280 at 25°C conforming to
d) For
filling,
a battery
grade dilute sulphuric
BS3031
oruse
better
(N.B. contaminated
acid withacid of
specific
gravity
1.270 - 1.280
at 25°
conforming
to
impurities
can seriously
damage
theClife
of the battery,
BS3031
or
better
(N.B.
contaminated
acid
with
in some cases reducing this to a few days. Do not use
impurities
canbatteries).
seriously damage the life of the battery,
acid from old
in some
cases reducing
this and
to a the
few battery
days. Do
not use
e) The
temperature
of the acid
should
acid
from
old
batteries).
both be at room temperature in the range of 15 - 30°C.
e) Fill
Theeach
temperature
acid
theof
battery
should
f)
cell with of
thethe
acid
to and
a level
8 - 15mm
above
both
be at
temperature
in the
of 15
- 30°
C.
the tops
of room
the plates.
Fill each
cell range
one after
the
other
f) Fill
each
cell
with
the
acid
to
a
level
of
8
15mm
above
and complete the filling in one operation.
the tops
ofbattery
the plates.
each
cell one
g) Leave
the
for 20Fill
- 30
minutes
andafter
thenthe other
and
complete
the filling involtage.
one operation.
measure
the open-circuit
If it is below 12.50V,
g) Leave
minutes
andadjust
then the
chargethe
thebattery
battery.forIf20
it is- 30
above
12.50V,
measure
the
open-circuit
voltage.
If
is
below
12.50V,
it
acid levels to the correct operating levels with dilute
charge
the
battery.
If
it
is
above
12.50V,
adjust
sulphuric acid of specific gravity 1.270 - 1.280. the
levels
to the
correct
levels
with dilute
h) acid
Fit the
normal
vent
plugs operating
and terminal
covers.
sulphuric
acid
of
specific
gravity
1.270
1.280.
i) Wash the battery with hot water and dry it.
h Performance checks on newly commissioned
j)
dry charged batteries using modern electronic digital
testers using conductance technology are not
d
recommended
(examples are - testers supplied by
testers
using
not
Midtronics
orconductance
Bosch). Thetechnology
results canare
be misleading
recommended
are - testers
supplied
by
until the battery(examples
has undergone
some service
use.
Midtronics or Bosch). The results can be misleading
until the battery has undergone some service use.
4. ELECTROLYTE LEVELS
(ACID) LEVELS IN SERVICE
P
PLEASE
READ BEFORE ADJUSTING ACID LEVELS
However,
ii) Do not top up to the maximum levels a battery that
needs charging as levels rise on charging. However,
if the levels are below the tops of the separators, top up
with distilled or de-ionised water until the separators
are just covered.
ii) Adjust levels to the maximum levels only after the
battery has stood for at least an hour after charging.
i Never overfill a battery as the acid may come out of
iii)
the vent plugs when the battery is being charged.
iv) Use only distilled or de-ionised water for topping up.
S
Sulphuric
acid should never be used except for the
initial filling of a battery.
a) When the battery is in service, the electrolyte levels
should be checked and adjusted to the levels given below.
b) If the battery has a maximum level line on the side of
the container fill to this level.
cc) If there is no maximum line but there are filling tubes
projecting from the bottom of the lid, fill to the bottom of
the tubes.
ALL YOU NEED TO KNOW
d) If there is no maximum line nor filling tubes in polypropylene batteries, fill to 7mm (0.25 inches) below the
bottom edge of the lid skirt.
d
e) If there is no filling tubes in hard rubber batteries, fill to
p
15mm (0.5 inches) above the tops of the separators.
b
e
To prevent the connector shorting
e) Disconnect the live connector second. If a CMS is
against the car, place an insulator such as a rubber
used, the connector will still remain live after it has been
glove over the connector.
disconnected. To prevent the connector shorting
f) Remove the hold-down clamps.
against the car, place an insulator such as a rubber
glove over the connector.
P
f) Remove the hold-down clamps.
5. SELECTING THE CORRECT
BATTERY FOR THE APPLICATION
CAR & COMMERCIAL VEHICLE (CV) BATTERIES
a) Select
the specified battery from the Application
C
Section
of this catalogue.
a
b) On S
24 Volt systems, or when 2 x 12 Volt batteries are
to do this
will result
in greatly
fitted
in parallel,Failure
both batteries
should
be replaced
at
b
rthe same time. Failure to do this will result in greatly
f
freduced battery life for the new battery that has been
t
Failure to do this will result in greatly
Failure to do this will result in greatly
fitted.
r
r
When
f batteries are joined in series, the negative
fterminal of one battery is connected to the positive
W
terminal
of the other, giving a total voltage of 24 Volts.
t
Thet Ampere-hour capacity of the system is the same
as that
T of the individual batteries.
When
a batteries are joined in parallel, the positive
terminals
of the two batteries are connected together,
W
The voltage
systemare
remains
andt the negative terminals
of the of
twothe
batteries
also
uconnected together. The voltage of the system remains
a
unchanged
at 12 Volts but
thevoltage
Ampere-hour
capacity
of
c
The
of the system
remains
voltage
of the system
remains
the usystem is double The
that of
the individual
batteries.
u
LEISURE
BATTERIES
t
a) Use
L the battery with the performance and size
recommended
by the equipment supplier.
a
b) Wer recommend that a leisure battery in a cycling
application,
should be sized so that it is not normally
b
The
discharged
to more than 50 percent state of charge.
a
lThis will ensure that the battery gives a good life. The
d
life Tof a battery regularly discharged by 50 percent is The
The
about
l 5 times that of a battery regularly discharged to
l
If this
represents
50 percent
state
100
percent
i.e.
a
load
of
3A
for
10
hours
will
discharge
a
oa battery by 30AH. If this represents 50 percent state
1
of charge,
webywould
recommend
a 60 AH50battery.
a battery
30AH.
If this represents
percent state
If this represents 50 percent state
o
o
c)
d)
e)
f)
g)
P
a)
b
c)
d)
a)
I
a)
a)
6. REMOVING AND INSTALLING
R
BATTERIES ON VEHICLES
R
w
R
REMOVING
BATTERIES
w
a
a) It is good practice to tell the customer that while you
w
will do your bestSwitch
to keepoff
the
settings,
it is
allmemory
electrical
loads and
p
be
lost.
rpossible these might
N.B.
On
some
Switch off all electrical loads and
b
b) cMake
sure
the
hand-brake
is
on,
and
that
the
car
is in
r n
N.B.loads
On some
Switch off all electrical
and
neutral
or park. Switch off all electrical loads and
c r
N.B. On some
remove the ignition keys from the car. N.B. On some
c
cars, the doors will lock when the battery is disconnected
s
so this is why the key should be removedInstall
from a
the car.
A
Also, switch off any non-factory fitted alarms.
C
Install a
c
not, turn
dc) Check
C t that the cigar lighter is still working - ifInstall
a
ignition key to the auxiliary position.
Install
a in
This can
result
d the C
Computer Memory Saver (CMS). This can result in
d
d) Disconnect the earth connector first - this is normally
t
This can result in
the negative on modern vehicles. This can result in
the loss of memory settings (please refer to the vehicle
h
handbook).
c
d)
e)
e)
e)
f)
g)
g)
g)
h)
i)
PREPARATION OF A BATTERY FOR FITTING
a) Check that the battery has the correct polarity for the
vehicle.
b) Check that the battery has the correct height for the
b vehicle - if a battery is too high it can short out on the
bonnet.
bonnet or the bottom of the seat, or it can damage the
It isbonnet.
good practice to place the old and new battery
side
side to
compare
polarities,
hold-downs
and
c) It by
is good
practice
to place
the old
and new battery
Some
batteries
have hold-downs at both sides and
performance
levels.
side by side
to compare polarities, hold-downs and
Only
the ones
used
for securing
thesides
battery
Some
batteries
have
hold-downs
at both
andon
performance
levels.
ends.
Only
the
ones
used
for
securing
the
battery
on
Some batteries have hold-downs at both sides and
Some
batteries
have
at both sides and
the
vehicle
need
toones
behold-downs
checked.
ends.
Only
the
used for securing the battery on
Only
the battery
ones used
for securing
Check
that the
and dry. the battery on
the vehicle
need to is
beclean
checked.
Check
that
the
vent
plugs
or
manifolds
are firmly in place.
d) Check that the battery is clean and dry.
Check
that
the
battery
has
a
voltage
of
above
e) Check that the vent plugs or manifolds
are 12.50V.
firmly in place.
Iff) not,
charge
usea another
that
has a12.50V.
Check
thatthe
thebattery
batteryorhas
voltage of
above
voltage
12.50V.
If not,above
charge
the battery or use another that has a
Ensure
the
two
terminal
caps are still fitted at this stage.
voltage above
12.50V.
g) Ensure the two terminal caps are still fitted at this stage.
damage
the any
battery
- placing
a heavytray
battery
onmight
a
Clear
away
items
on the
battery
which
PREPARATION
OF THE
VEHICLE
damage
the
battery
placing
a
heavy
battery
on
a might
a) Clear away any items on the battery tray which
piece
of sharp
can puncture
bottom
of theon a
damage
thegrit
battery
- placing the
a heavy
battery
damage
the battery - placing a heavy battery on a
battery.
piece of sharp grit can puncture the bottom of the
battery.
the
tray arethat
clean
corrosionthe
free
- if there clamps
is any and
b) Check
the and
connectors,
hold-down
corrosion,
remove
the trayhot
arewater
cleanwill
andinstantly
corrosion
free - this.
if there is any
Check
that thehot
alternator
drive
belt tension
correct
corrosion,
water will
instantly
removeisthis.
(refer
to
the
vehicle
handbook
or
service
manual).
c) Check that the alternator drive belt tension is correct
particularly
the charging
system
of thesystem
vehicle,
be
It is(refer
recommended
that handbook
the
electrical
and
to the vehicle
or service manual).
particularly
the
charging
system
of
the
vehicle,
d) It is recommended that the electrical systembe
and
checked
to make
it is operating
(refer
particularly
thesure
charging
system ofcorrectly
the vehicle,
beto
particularly
the charging
of
the vehicle, be
the checked
vehicle handbook
or system
service
manual).
to make sure
it is operating
correctly (refer to
Fit and tighten the hold-down clamps. These should
the vehicle handbook or service manual).
Fit
and tightenTHE
the hold-down
INSTALLING
BATTERYclamps. These should
be
tight
enough
to
secure
the battery
and not
allow
it to
a) Fit and tighten the hold-down
clamps.
These
should
Fit
tighten the hold-down clamps. These should
m and
be tight enough to secure the battery and not allow it to
move - DO NOT OVER TIGHTEN.
DO NOT OVER TIGHTEN.
b) Connect the live connector first to the correct battery
DO NOT
TIGHTEN.
terminal (usually
the OVER
positive)
after removing the
DO NOT OVER TIGHTEN.
terminal cap. DO NOT OVER TIGHTEN.
DO NOT OVER
DOTIGHTEN.
NOT
c) Connect the earth connector
to theOVER
other TIGHTEN.
terminal after
removing the terminal cap. DO NOT OVER TIGHTEN.
removing the terminal cap. DO NOT OVER TIGHTEN.
d) Place both terminal caps on the old battery that has
Place both
terminal
caps
on the
oldcomponents
battery that that
has
Replace
onto
the new
battery,
any
been removed from the vehicle to avoid the possibility
been
removed
from
the
vehicle
to
avoid
the
possibility
have
been
taken
from
the
old
battery
such
as
exhaust
Replace
onto
the new battery, any components that
of short
circuits.
of
short
circuits.
have
been
taken
fromnew
the battery,
old battery
as exhaust
e) Replace
onto the
anysuch
components
that
Replace onto the new battery, any components that
have been taken from the old battery such as exhaust
have been taken from the old battery such as exhaust
tubes, vent elbows, terminal covers, removable holdtubes, vent elbows, terminal covers, removable holddown strips (widgets) etc.
down
strips (widgets)
etc. a small amount lightly on the
disadvantage
in smearing
f) The use of petroleum-jelly (Vaseline) is not necessary
The
use
of
petroleum-jelly
is not
necessary
This
is
still
recommended
for
hard
rubber
disadvantage
smearing
a(Vaseline)
small
amount
onno
the
on modernin
polypropylene
batteries,
but lightly
there is
on modern This
polypropylene
batteries,
but
there
is
no
recommended
hard rubber
disadvantageisinstill
smearing
a small for
amount
lightly on the
disadvantage in smearing a small amount lightly on the
terminals. This is still recommended for hard rubber
terminals. This is still recommended for hard rubber
batteries - Do not use grease.
batteries - Do not use grease.
g) Remove the CMS.
h) Start the engine.
Start the engine.
i) For non-automotive applications, install the battery in
For non-automotive applications, install the battery in
line with the equipment supplier's recommendations.
l
ALL YOU NEED TO KNOW
7.
i CHARGING OFF-VEHICLE
working principles and the procedures for using these
is given below.
3
PLEASE READ BEFORE CHARGING BATTERIES
i) Do NOT charge a battery if it's temperature is below
bC as the electrolyte may have frozen.
3°
i
ii) Charging the battery on the vehicle is not recommended.
c
to Section 6 for information about removingDo
thenot
iii) Refer
c
from the vehicle.
battery
iv) 'Sealed' vehicle batteries should be charged only on
constant potential chargers or 'smart' chargers. Do not
charge on constant current chargers or boost chargers.
a
vehicle batteries do not allow any access to
'Sealed'
n electrolyte and so cannot be topped up as there are
the
v no removable vent plugs or manifolds - the battery is
s to vent gases through breathing holes and so is
able
not strictly sealed.
v) A new, unused battery with a voltage below 11.00V
Gshould be scrapped and not charged (see Maintenance
C of Stock section).
T
The sectionsFOR
following
give details
GENERAL PROCEDURE
ALL TYPES
OF for
d
CHARGERS
a This section gives common information for allIftypes
theseofare
b
chargers.
The sections following give details for
o
Do not
different
types of charger.
f
a) Check the electrolyte levels in all the cells. If these are
a
below
the tops of the separators, top up with distilled
b or de-ionised water to the top of the separators. Do not
fillc to a higher level before charging - adjust the levels
c charging.
If you are using a constant
after
b) Ifpyou are using a constant current charger or boost
charger, remove the vent plugs or manifolds before
c charging (see below). If you are using a constant
d potential or a 'smart' charger there is no need to remove
p vent plugs or manifolds.
the
l
c) Check
that the charger is switched off.
d)e When fitting the charger to the battery, connect the
c
positive
lead to the positive terminal and the negative
f lead to the negative terminal.
g
e) Switch
on the charger (see below for the correct
charging conditions depending on your type of charger).
f)g Stop charging if the battery begins to gas freely (some
h gassing is normal during the last stages of charging) or
if gthe battery temperature rises above 50°C.
b
g) Switch
off the charger.
h) Itsis good practice to wait for about 20 minutes for the
i gasses to clear before removing the leads from the
n
battery
as some chargers remain live and can cause a
j spark.
i)k Check the electrolyte levels in all the cells and top up if
l necessary.
o vent plugs or manifolds if these have been removed.
j) Refit
c
k) Wash
the battery with hot water and dry it.
l) N.B. Many customers severely underestimate the amount
of time necessary to charge a flat battery - this results in
customers returning batteries saying that they have
charged the battery but that it is still not holding a charge.
INDEX
w
SECTION
CHARTER TYPE
is given below.
A
Constant Current Chargers
B
Constant
Potential Chargers
I
C
Modified
Constant
SECTION CHARTER TYPE Potential Chargers
'Smart Chargers'
AD
Constant
Current Chargers
E
Boost Chargers
B
Constant Potential Chargers
C
Modified Constant Potential Chargers
A CONSTANT CURRENT CHARGERS
D
'Smart Chargers'
These maintain a fixed, constant, preset current through
the charging period irrespective of the battery on-charge
A voltage.
These maintain a fixed, constant, preset current through
Charging
Procedure
with Constant
Current
the charging
period irrespective
of the
batteryChargers
on-charge
1voltage.
Ideally, charge each battery on a separate charger unit.
If this is not possible, charge batteries in parallel
C because it is not possible to control the amount of
current passing through each battery.
I If batteries in different states-of-charge are being charged
bin series, each battery should be removed as soon as
it is charged (if you wait until the last battery is charged,
of the
batteriesstates-of-charge
will be overcharged.
Ifsome
batteries
in different
are being charged
2inMeasure
the
open-circuit
voltage
of the battery.
series, each battery should
be removed
as soonTo
as
obtain
a
stable
voltage,
the
battery
should
have been
it is charged (if you wait until the last batterynot
is charged,
usedof
orthe
charged
for awill
minimum
of 3 hours prior to
some
batteries
be overcharged.
checking
the
voltage.
2 Measure the open-circuit voltage of the battery. To
3obtain
Charge
the battery
at the
rate
a stable
voltage,
therecommended
battery should charge
not have
been
(see
battery
specifications
section).
If
you
cannot
used or charged for a minimum of 3 hours prior to set
the recommended
checking
the voltage.rate, extend or reduce the charging
time
on
a
rata at
basis.
For example, ifcharge
the rate
3 Charge thepro
battery
the recommended
recommendation
is
to
charge
the
battery
4.0A set
for 6
(see battery specifications section). If you at
cannot
hours
(24AH = 4.0A
x 6),
charge
the battery
for 12 hours
the
recommended
rate,
extend
or reduce
the charging
if you can only set the charger at 2.0A (24AH = 2.0A x 12)
4recommendation
Charge the battery
the number
of hours
shown
is toforcharge
the battery
at 4.0A
for in
6 the
table (24AH
below =
depending
the open-circuit
hours
4.0A x 6),on
charge
the battery voltage.
for 12 hours
if the
hasata2.0A
voltage
of 12.16V,
if For
youexample,
can only set
thebattery
charger
(24AH
= 2.0A x 12)
charge
it
for
10
hours
at
the
recommended
chargeinrate.
4 Charge the battery for the number of hours shown
the
table below depending on the open-circuit voltage.
OPEN
CIRCUIT
For
example,
if the battery hasCHARGING
a voltage of 12.16V,
VOLTAGE
(V)
TIME (HOURS)
charge it for 10 hours at the recommended
charge rate.
Above 12.40
4
6
O12.31 - 12.40
12.21
12.30
8
V
12.11
12.20
10
Above 12.40
4
12.01- -12.40
12.10
12.31
612
11.91
12.00
12.21 - 12.30
814
11.81
11.90
16
12.11 - 12.20
10
11.71
11.80
18
12.01 - 12.10
12
11.00- -12.00
11.70
20
11.91
14
Below
11.00
See
11.81 - 11.90
16 paragraph 5 below
11.71 - 11.80
18
511.00
If you- are
charging a battery below
11.70
20 11.00
(overdischarged)
that
has
been
in service, a
Below 11.00
See paragraph
5 specialised
below
charger capable of providing a very high charging voltage
be necessary,
the below
recommended
5 Ifmay
you are
charging a and
battery
11.00 current may
not
be
obtainable
at
first.
In
this
case,
monitor the
(
current and adjust as necessary during the charge.
If a battery has become overdischarged, it will have lost
both life and performanceInbecause
ofmonitor
irreversible
this case,
the
sulphation.
Charging
may
reduce
further
it's potential life.
c
Charging may reduce further it's potential life.
ALL YOU NEED TO KNOW
7. CHARGING OFF-VEHICLE
B CONSTANT POTENTIAL CHARGERS
These maintain a fixed, constant, preset voltage throughout the charging period. The current cannot be set and
will fall as the battery state-of-charge increases.
The current cannot be set and
Charging Procedure with Constant Potential and
w
Modified Constant Potential Chargers
1 These chargers are normally designed to charge one
battery at a time.
2 Stop charging when the battery is gassing freely and
the battery voltage shows no increase over a period of
at least 2 hours.
3 N.B. The majority of constant potential chargers are
incapable of charging a severely overdischarged
(below 11.00V) battery in a realistic period of time. A
minimum of 24 hours is normal. Also, It may be
impossible to charge an overdischarged battery.
A
m
Also, It may be
C MODIFIED CONSTANT POTENTIAL CHARGERS
i
The majority of commercial chargers, particularly
home chargers, are this type, and allow neither the
voltage nor the current to be preset.
h
Charging Procedure with Modified Constant
Potential Chargers
1 Use the same procedure for Constant Potential Chargers
D 'SMART' CHARGERS
The latest generation of chargers, is able to check the
battery condition and to supply automatically a
D
controlled charge that will charge the battery in the
fastest time without overcharging it at the end of the
b
charge. Some 'Smart' chargers have a special
setting for all-calcium batteries and will charge these
from flat, which most other chargers are unable to do.
Some 'Smart' chargers have a special
s
Charging Procedures with 'Smart Chargers
f
1 Follow the manufacturers instructions.
2 These chargers should be able to charge
'Smart Chargers
overdischarged (below 11.00V) batteries. N.B. Some
have a special setting for all-calcium batteries.
N.B. Some
E BOOST CHARGERS
h
These provide a very high initial current, and are used
mainly to put some charge into a flat battery when it is
needed urgently by the customer. The current falls as
the battery state-of-charge increases, and the battery
temperature is monitored to make The
surecurrent
that it does
falls as
not overheat.
t
Charging Procedures with Boost Chargers
n
1 Boost charging is not recommended except in
exceptional circumstances e.g. a stranded customer,
C
as this will reduce battery life, especially if a battery
1
is boost-charged more than once.
e
2 Never boost-charge any battery that is below 11.00V
a
as it will be too sulphated to accept a charge; scrap
i
the battery or charge normally.
2
3 Only use a boost-charger that limits the charging
a
voltage to a maximum of 14.2 Volts and that has a
t
temperature monitor.
3
4 Follow carefully the charger-manufacturer's instructions.
v
t
8. CHECKING BATTERY PERFORMANCE
CCA Testing using Digital Conductance Battery Testers
There are many different types of hand held Digital Conductance
Battery Testers on the market; Please Note
a) They are not a reliable method of checking the fully developed
There are many different types of hand held Digital Conductance
cold-cranking performance of a NEW battery. They are designed
for the testing and evaluation of suspect or used batteries.
b) Different makes of tester, and even different testers of the same
make can give different results.
c) Plate design can affect the readings. Different readings will be
experienced for batteries with standard lead-antimony plates from
those with calcium-hybrid or calcium-calcium plates. Flooded
batteries will give different readings to AGM or GEL batteries.
e) The condition of leads and terminal connectors can influence
the reading on hand held testers.
f) A battery that is aged may still be serviceable but because of
wear & tear may only give a reduced health reading.
the reading on hand held testers.
Open-Circuit Voltage and High-Rate Discharge Testers
f) A battery that is aged may still be serviceable but because of
a) Measure the open-circuit voltage of the battery using a
digital voltmeter or a multimeter. To obtain a stable
voltage, the battery should not have been used or
charged for a minimum of 3 hours before checking the
To obtain a stable
voltage.
b) If the voltage is below 12.60V, charge the battery in
accordance with Section 7 (Charging Off-Vehicle) above.
Note: This type of tester will only give an accurate result
on a fully-charged battery. A common mistake is to use
this type of tester on a discharged battery, and to judge
that the battery is faulty is a cell is seen to 'boil'. A
A common mistake is to use
boiling' cell on a flat battery does not mean that the
battery is faulty.
A
c) Apply a current-load equal to three times the 20HR rate
for 10 seconds. e.g. battery capacity 45 ampere
hour (AH) = 3 x 45 = 135 amps. The voltage during
discharge should be stable at 9.6 volts or over.
for 10 seconds. e.g. battery capacity 45 ampere
Use an approved calibrated tester.
The voltage during
d) If the voltage after 15 seconds is stable and above 9.60V,
the battery is in a satisfactory condition with no faults.
e) If the voltage is below 9.60V after 15 seconds and it is
d
unstable, normally falling quickly, the battery should be
replaced.
'DROP TESTERS'
unstable, normally falling quickly, the battery should be
a) 'Drop Testers ' have 2 spikes that are pressed into the
tops of the battery terminals and a simple voltmeter to
check the discharge voltage.
9. MAINTENANCE IN SERVICE
General
9. MAINTENANCE IN SERVICE
a) Always refer to the information contained in the handbook
or brochure supplied with the vehicle or equipment.
General
Definition of Maintenance-Free
a) Always refer to the information contained in the handbook
a) All Shield starter batteries for cars and commercial
or brochure supplied with the vehicle or equipment.
vehicles conform to the relevant sections of BS EN 60095
Definition of Maintenance-Free
for maintenance-free characteristics.
a) All Shield starter batteries for cars and commercial
This means that in normal vehicle applications and
vehicles conform to the relevant sections of BS EN 60095
temperate climate operation, it is not necessary to add
for maintenance-free characteristics.
water.
This means that in normal vehicle applications and
b) Shield batteries are designed to be topped up with water
temperate climate operation, it is not necessary to add
if water should be lost owing to, for example, a charging
water.
system fault, prolonged operation in hot climates,
b) Shield batteries are designed to be topped up with water
excessive off-vehicle charging etc.
if water should be lost owing to, for example, a charging
c) Note: The term maintenance-free applies only when the
system fault, prolonged operation in hot climates,
battery is used in an approved automotive or commercial
excessive off-vehicle charging etc.
application.
ALL YOU NEED TO KNOW
c) Note: The term maintenance-free applies only when the
battery is used in an approved automotive or commercial
application.
D
a
Definition of Low Maintenance
a
a) Low maintenance batteries in normal vehicle
w
applications in temperate climate operation need
b
water-addition only at yearly intervals.
w
b) Shield batteries are designed to be topped up with
c
water if water should be lost owing to, for example, a
c
charging system fault, prolonged operation in hot
c
climates, excessive of-vehicle charging etc.
b
c) Note: The term low maintenance applies only when the
a
battery is used in an approved commercial vehicle
application.
B
a
Battery Maintenance in Automotive Applications
v
a) Carry out the checks below at the recommended
b
vehicle service intervals.
n
b) Check the electrolyte-level and top up with water if
a
necessary. See Section 4 (Electrolyte-Levels) for details
b
about how to do this. (As explained above, it should not
e
be necessary to add water unless the battery has
c
encountered exceptional conditions).
v
c) Check that the battery is clean and dry and that the
d
vents are not obstructed.
c
d) Check that the terminal-connectors and the hold-down
e
clamps are securely connected and corrosion free.
e
e) If the battery is on a vehicle that is not to be used for an
f
Refer to Section 6 (Removing
extended period (more than 1 month), disconnect it
B
Modern cars have electrical
from the vehicle. Refer to Section 6 (Removing
a
Batteries) to do this. Modern cars have electrical
w
accessories that slowly discharge the battery even
S
when the ignition key has been removed.
p
Some accessories such as alarms, trackers, and
a few weeks.
phones can cause a battery to become discharged in
f
a few weeks.
r
f) Fully charge the battery before storage and give it a
refreshing charge every 3 months (see Section 7
Charging-Off Vehicle).
B
a
b)
c)
d)
e)
f)
g)
U
a)
b)
Battery Maintenance in Non-Automotive Float
Applications
a) Typical applications are motor-generators, stand-by
applications etc. The Leisure Battery range is
recommended for these applications - standard vehicle
applications etc. The Leisure Battery range is
batteries are not suitable.
recommended for these applications - standard vehicle
b) Batteries used in these applications should be changed
batteries are not suitable.
every 2 years or more frequently. (Continuous charging,
Batteries used in these applications should be changed
even from a well-controlled charging system, will result in
every 2 years or more frequently. (Continuous charging,
internal degradation of the battery. This could result in
even from a well-controlled charging system, will result in
the battery not giving it's predicted output when required
internal degradation of the battery. This could result in
even though the battery appears to be fully-charged).
the battery not giving it's predicted output when required
c) Ensure that the battery is always kept in as high a
even though the battery appears to be fully-charged).
state-of-charge as possible without causing excessive
Ensure that the battery is always kept in as high a
overcharge. Always recharge immediately after use.
s
d) Check the electrolyte levels on a regular basis dependent
o
Always recharge immediately after use.
upon use, but not less frequently than monthly. Charging
Check the electrolyte levels on a regular basis dependent
batteries continuously on a non-vehicle charging system
upon use, but not less frequently than monthly. Charging
may result in a higher rate of water loss.
batteries continuously on a non-vehicle charging system
e) Check that the battery is clean and dry and that the vents
may result in a higher rate of water loss.
are not obstructed.
Check that the battery is clean and dry and that the vents
f) If the battery is not to be used for an extended period
are not obstructed.
(more than 1 moth), fully charge it before storage, and
If the battery is not to be used for an extended period
give it a refreshing charge every 3 months. See
(more than 1 moth), fully charge it before storage, and
Section 7. Charging Off-Vehicle.
give it a refreshing charge every 3 months. See
g) Best practice is to define a regular maintenance-routine,
Section 7. Charging Off-Vehicle.
and to record the results. This should include such
Best practice is to define a regular maintenance-routine,
variables as the amount of water added to each cell,
and to record the results. This should include such
specific gravities in each cell, battery voltage etc.
variables as the amount of water added to each cell,
specific gravities in each cell, battery voltage etc.
Use of Battery Additives
a) Shield Batteries do not recommend the use of battery
additives.
Shield Batteries do not recommend the use of battery
b) The use of these invalidates the guarantee.
additives.
The use of these invalidates the guarantee.
Label Information
L
Note Operating Instructions
N
Battery Maintenance in Non-Automotive Traction
and Deep Discharge Applications
c
The Leisure / Semi-Traction
a) Typical applications are lawnmowers, electric wheelB
chairs, caravans, etc. The Leisure / Semi-Traction
Battery range is recommended for these applications
b
standard vehicle batteries are not suitable.
Always recharge
b) Ensure that the battery is always kept in as high a
i
state-of-charge as possible. Always recharge
c
immediately after use.
c) Check the electrolyte levels on a regular basis
dependent upon use.
s
Charging batteries regularly on a non-vehicle charging
system may result in a higher rate of water-loss.
d) Check that the battery is clean and dry and that the
e
vents are not obstructed.
e) If the battery is not to be used for an extended period
(more than 1 month), fully charge it before storage, and
S
give it a refreshing charge every 3 months. See
Section 7. Charging Off-Vehicle.
Shield eyes - eye protection must be worn
Shield eyes - eye protection must be worn
Keep away from children
Keep away from children
Battery acid - corrosive and poisonous
Battery acid - corrosive and poisonous
No smoking - no naked flames - no sparks
No smoking - no naked flames - no sparks
Explosive gases
Explosive gases
Never dispose of as domestic waste - take to
a designated waste reclamation site
Never dispose of as domestic waste - take to
a designated waste reclamation site
B
Battery is recyclable - follow local recycling &
reclamation procedures