BATTERY MAINTENANCE
AND TROUBLESHOOTING
BATTERY
MAINTENANCE
BATTERY MAINTENANCE
Maintenance
Safety
Maintenance frequency
Procedures
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BATTERY MAINTENANCE
Safety
Use insulated tools
Electrolyte can cause severe burns
Always applied safety rules and used protection
Never use matches or other open flame near batteries
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BATTERY MAINTENANCE
Maintenance frequency
Typical maintenance interval
* Interval to be calculated for each battery type according to operation conditions
4/20
BATTERY MAINTENANCE
Extended maintenance interval
Depending on
n Battery type
n Site conditions
n Charging equipment
n Top up requirement
n Operating conditions
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BATTERY MAINTENANCE
Maintenance operations
Check Corrective actions
n Electrolyte levels n Top up if necessary
n Charging voltage and charger n Charger adjustments
conditions
n record if required
n Physical conditions n Clean and correct as required
n Cleanliness n Report any abnormalities
n Leaks
n Connectors and cables
n Racks
6/20
BATTERY MAINTENANCE
Maintenance operations
Watch out for:
Electrolyte level: Connection and vent:
n High water consumption n Broken cables
n No water consumption n Loose terminals
n Vent cap damage
Charging conditions:
n High or low charging voltage Physical and site conditions:
n Charger alarms n Rack problems
Cleanliness:
n Dirty battery
n Salt accumulation
n Leaks and spillage
n Terminal corrosion
7/20
BATTERY MAINTENANCE
High water usage = over charging
Check: Corrective actions:
n for high charging n Adjust charging voltage,
voltage if required
n for cells with low n Replace cell
voltage or short circuit
8/20
BATTERY MAINTENANCE
No water usage = under charging
Check: Corrective actions:
n for low charging
voltage n Adjust charging voltage,
if required
n charging current
n for open circuit n Re-established the
conditions contact
9/20
BATTERY MAINTENANCE
Low water consumption of individual cells
= partial or total cell short circuits
Check: Corrective actions:
n Cell voltages on
n High rate charge to
charge
remove soft shorts
n for short circuits on
n Replace cells with hard
those cells
shorts
10/20
BATTERY MAINTENANCE
Low individual cell voltage
= partial or total cell short circuits
Check: Corrective actions:
n for short circuits on n High rate charge to
those cells remove soft shorts
n Replace cells with hard
shorts
11/20
BATTERY MAINTENANCE
Dirty battery = site conditions
Check: Corrective actions:
n Environment. n Clean with soft brush
Improve if possible or water (use only
water)
12/20
BATTERY MAINTENANCE
Salt accumulation = potassium carbonates
from electrolyte
Check: Corrective actions:
n for leaks around n Clean minor deposits
terminal and vent caps with water
n for overcharge n Avoid overfilling
n Repair or replace as
n for broken vent cap
appropriate
13/20
BATTERY MAINTENANCE
Leaks and spillage
Check: Corrective actions:
n containers for cracks
n Repair or replace as
and damage
appropriate
n for vent cap damage
n for overcharge n Avoid overfilling
14/20
BATTERY MAINTENANCE
Terminal corrosion
Check: Corrective actions:
n Inspect for corrosion n Clean with soft brush or
damage with damp cloth
n Apply corrosion
protection
n Replace if necessary
15/20
BATTERY MAINTENANCE
Broken cables = mechanic impact, hot spots
Check: Corrective actions:
n conductors and lugs
n Replace if required
n insulation
16/20
BATTERY MAINTENANCE
Loose terminals
Check: Corrective actions:
n that the spring washer n Retorque if necessary
is completely flat (see installation and
against the connector operating instruction
sheets for torque value)
17/20
BATTERY MAINTENANCE
Vent caps
Check: Corrective actions:
n integrity of vent caps
n Wash to dissolve
n no physical damage potassium
n proper closing carbonates in water
n no potassium n replace damaged
carbonates accumulation vent caps
18/20
BATTERY MAINTENANCE
Racks
Check: Corrective actions:
n rails for physical n Replace badly corroded
integrity or damaged rack parts
19/20
BATTERY MAINTENANCE
Charger alarm
Charger alarms such as ground
fault and charge fail may be an
indication of battery problems
Ground fault may be caused by
electrolyte leaks or spillage (as
described)
Charge fail may be caused by an
open circuit
Check all connections
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