Batteries should be carefully inspected on a regular basis in order to detect and correct potential problems before they can do harm.

Inspection Guidelines

1. Examine the outside appearance of the battery.

• Look for cracks in the container.
• The top of the battery, posts and connections should be free of dirt, fluids and corrosion.
• Repair or replace any damaged batteries.

2. Check for any fluids on or around the battery.

• Any fluids on or around the battery may indicate that electrolyte is spilling, leaching or leaking out.
• Leaking batteries must be replaced.

3. Check all battery cables and connections.

• Look closely for loose or damaged parts.
• Battery cables should be intact; broken or frayed cables can be extremely hazardous.
• Replace any cable that looks suspicious.
• Tighten all wiring connections to the proper specification. Make sure there is good contact with the terminals.

Warning: Do not over-tighten terminals as this can result in post breakage, post meltdown or fire.

Visual inspection alone is not sufficient to determine the overall health of the battery. Both open-circuit voltage and specific gravity readings can give a good indication of the battery’s charge level, age and health. Routine voltage and gravity checks will not only show the state of charge but also help spot signs of improper care, such as undercharging and over-watering and possibly even locate a bad or weak battery.

Flooded batteries need water. More importantly, water must be done at the right time and in the right amount or else the battery’s performance and longevity suffers.

Water should always be added after fully charging the battery. Prior to charging, there should be enough water to cover the plates. If the battery has been discharged (partially or fully), the water level should also be above the plates. Keeping the water at the correct level after a full charge will prevent having to worry about the water level at a different state of charge.

Depending on the climate, charging methods, application etc, we recommend that batteries be checked once a month.

Important things to remember:

• Do not allow plates to be exposed to air. This will damage (corrode) the plates.
• Do not use batteries when level of electrolyte is below the plates. This will cause irreversible damage.
• Do not fill the water level in the filling well to the cap. This most likely will cause the battery to overflow acid, consequently losing capacity and causing a corrosive mess.
• Do not use water with a high mineral content. Use distilled or deionised water only.

Caution: The electrolyte is a solution of acid and water, so skin contact should be avoided.

Procedure:

• Remove vent caps.
• Check electrolyte level; the minimum level must be over the plates no more than 1/8th of an inch or 1/8th of an inch above the fill well.
• If the level is low, top up with de-ionised water. A piece of rubber can be used safely as a dipstick to help determine this level.
• Clean, replace and tighten all vent caps.

Warning: Never add acid to a battery.

Equalising is an overcharge performed on lead-acid batteries after they have been fully charged. It helps eliminate stratification and sulphation, two conditions that can reduce the overall performance of a battery. It is recommended that batteries be equalised periodically, ranging anywhere from once a month to once or twice a year. AGM or Gel batteries should never be equalised.

Procedure:

• Verify that batteries are flooded/wet.
• Remove all loads from the batteries.
• Connect battery charger.  
• Set charger to equalising mode.
• Start charging batteries.
• Batteries will begin gassing and bubbling vigorously.
• Take specific gravity readings every hour.
• Equalisation is complete when specific gravity values no longer rise during the gassing stage.

Note: Many chargers do not have an equalisation setting so this procedure cannot be carried out.

Batteries seem to attract dust, dirt and grime. Keeping them clean will help you to spot trouble signs if they appear and avoid problems associated with grime.

• Check that all vent caps are tightly in place.
• Clean the battery top with a cloth or brush and a solution of baking soda and water. Do not allow any cleaning solution or other foreign matter to get inside the battery.
• Rinse with water and dry with a clean cloth.
• Clean battery terminals and the inside of cable clamps with a post and clamp cleaner. Clean terminals will have a bright metallic shine.
• Reconnect the clamps to the terminals and thinly coat them with petroleum jelly (Vaseline) to prevent corrosion.
• Keep the area around batteries clean and dry.

Procedure:

• Completely charge the battery before storing.
• Store the battery in a cool, dry location, protected from the elements.
• During storage, monitor the specific gravity (flooded batteries) or voltage. Stored batteries should be given a boost charge when they show a 70% state of discharge.
• Completely charge the battery before re-activating.
• For optimum performance, equalise the batteries (flooded batteries) before putting them back into service. (See section on equalising)

There are many types of chargers available today. They are usually rated by their start rate, the rate in amperes that the charger will supply at the beginning of the charge cycle. When selecting a charger, the charge rate should be between 10% and 13% of the battery’s 20-hour AH capacity. Chargers with lower ratings can be used but the charging time will be increased.

Charging batteries properly requires administering the right amount of current at the right voltage. Most charging equipment automatically regulates these values. Some chargers allow the user to set these values. The original instructions for your charging equipment should be referenced for proper charging.

Important things to remember:

• Always follow instructions from the charger manufacturer.
• Batteries should be charged after each period of use.
• Charge only in well-ventilated areas. Keep sparks or flames away from a charging battery.
• Verify voltage settings are correct.
• Check electrolyte level.
• Tighten all vent caps before charging.
• Do not overcharge or undercharge the batteries.
• Avoid charging at temperatures above 120° F.

Discharging batteries is entirely a function of your particular application. However, below is a list of helpful items:

• Shallow discharges will result in a longer battery life.
• 50% (or less) discharges are recommended.
• 80% discharge is the maximum safe discharge.
• Do not fully discharge flooded batteries (80% or more). This will damage the battery.
• Do not leave batteries deeply discharged for any length of time.
• Lead-acid batteries do not develop a memory and need not be fully discharged before recharging

Periods of inactivity can be extremely harmful to lead acid batteries. When placing a battery into storage, follow the recommendations below to insure that the battery remains healthy and ready for use.

Note: Storing, charging or operating batteries on concrete is perfectly ok.

The most important things to avoid:

1. Freezing – avoid locations where freezing temperature is expected. Keeping a battery at a high state of charge will also prevent freezing. Freezing results in irreparable damage to a battery’s plates and container.

2. Heat – avoid direct exposure to heat sources, such as radiators or space heaters. Temperatures above 80°F accelerate the battery’s self-discharge characteristics.