| |
When a battery does not supply
power, the following procedure should be undertaken. |
| |
* Check whether the battery is damaged or
merely discharged. |
| |
* If the battery is deemed to be damaged.
try to detect the cause of the damage. in this case, consider
|
| |
the following possible causes. |
| |
a. The battery itself |
| |
b. other electrical equipment |
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c. Improper maintenance |
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* If the fault is determined, take appropriate
countermeasures. |
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* If the battery is merely discharged, charge
battery |
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|
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¢º How
to determine whether battery is damaged or merely discharged. |
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Most batteries returned for the
reason of malfunction are found only to be discharged.
To discriminate |
| |
between these two condition, the following
three-step examination procedure is convenient except
|
| |
whether damage is easily visible, such as
a conrainer, cover, or vent. |
| |
a. Check battery's exterior, voltage, electrolyte
level and specific gravity. |
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b. Perform charging test. |
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c. Perform cranking test. |
| |
|
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The first examination step is basic procedure
nd will suggest whether the battery is damaged or merely
|
| |
discharged. if the battery is fully chargeable
in the second step, it may be considered not to be faulty
in |
| |
most cases. If the battery passes the third
step successfully, it can safely be determined as normal. |
| |
|
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¢º
Inspection of battery exterior,voltage, electrolyte level
and specific gravity. |
| |
Before performing charging test, inspect
the battery in questing for the following four points. |
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|
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1) Battery exterior
|
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a. Whether or not container,cover, terminal, vent plug
are damaged.
|
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b. Whether or not positive and negative plates are
whitened.
|
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c. Whether or not positive grids are corroded and broken.
|
| |
d. Whether or not sediment has piled up to the bottom
of the plates and caused a short-circuiting.
|
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2) Voltage
|
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Check individual cell voltage and total voltage.
|
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3) Electrolte level
|
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Normal, roo low, or too high.
|
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4) Specific gravity of electrolyte |
| |
Should be more than 1.200 on checking the
cells in order to determine whether the battery is damaged
|
| |
or not, compare the inspection results with
the following chat. |
| |
Part to be inspected
|
Normal Battery
|
Damaged/probably
Damaged battery
|
Countermeasure
|
Exterior, containier,
cover and plug
|
neither cracked
nor broken
|
cracked or broken
|
For container and
coverreplace the battery itself.For ventplug, replacethe
new one. |
Container, cover nad container-cover
joint
|
No electrolyte leakage
|
electrolyte leakage
|
Replace the battery
itself. |
Terminal
|
Neither corroded
norbroken
|
corroded or broken
|
When terminal are
corroded, clean and grease them. For broken, replage
the battery itself. |
Elements
(plates group)
|
Positive plates are chocolate-colored.
Negative plate
|
Plates are whitened. (sulfation) Positive
plate grids arecorroded and broken.
|
Replace the battery itself. |
Sediment
|
Small quantity
|
Piled up to bottom
of plates
|
Replace the battery
itself. |
Voltage
|
Total voltage, more than 12V.Each
cell voltage,1.95v over.
|
Total voltage, 12V below.One or more
cells,1.95V below.
|
Carry out charging test. |
Electrolyte level
|
Between the upper
and the lower level
|
Below the lower
level
|
Carry out charging
test after filling |
Sp.Gr of electrolyte
|
Each cell, 1.280 over
|
One or more cells, 1.100
below
|
Carry out charging test.
|
|
| |
|
| |
¢º Charging
test |
| |
When the battery is suspected of some damage
as a result of an examination of voltage, electrolyte
level |
| |
and specific gravity, it should then undergo
a charging test. |
| |
The charging current should be on designated
for low-rate charging or a rate calculated by dividing
the |
| |
battery's normal capacity by 10. Thecharging
time should depend upon the discharged state. |
| |
When the eletrolyte level in individual
cell is lower than designed, purified water should be
aded to the |
| |
cells so that the new level is slightly
below the upper level. |
| |
Measurements of battery voltage and specific
gravity of the electrolyte should be carried out immediately
|
| |
after the start of charging, again an hour
rate, a few more times,if necessary, and once more just
before |
| |
the end of charging. |
| |
|
| |
1) When total voltage is about 12volts after the start
of charging and than rises gradually to 12.6-12.8 volts
|
| |
in 30 minutes or an hour, the battery is probably
free of damage.
|
| |
2) When charging approaches completion, all the cells
should be actively generating gas, total voltage
|
| |
is over 15 volts, and the sp.gr of the electrolyte
is 1.260-1.280. The battery is probably free of damage.
|
| |
3) If a cell does not give off gas, the sp.gr of electrolyte
in the cell is lower than designated. When
|
| |
charging approaches completion, the cell may be short-circuited.
|
| |
4) When the sp.gr of the electrolyte exceeds
1.29. at the cplpletion of charging, adjust the sp.gr
to a |
| |
required standard. |
| |
In the charging test, generally speak-ing,
the battery may be determined free of damagr by good charging
|
| |
result, from rising of voltage and rising
of the sp.gr of electrolyte. |
| |
|
| |
¢º Cranking
ability test |
| |
A high-rate discharging test should be performed
with the same current as that rated for the starter. |
| |
In general, however, it may be conducted
with a three times current of 20 hour rate or 10 hour
rate |
| |
capacity. |
| |
|
| |
Test instructions |
| |
Battery condition
|
Full changed state |
Discharging current
|
A three times current
of nominalcapacity.
(Ex:about
150 amperes for a 50 ah battery) |
Final voltage after
Discharging
|
1 Volt per cell |
Battery temperature
|
Normal temperature |
Measurement to be
Performed
|
5 Seconds voltage
and the period of time required to drop the voltage
down to one volt per cell. |
|
| |
Examination
test results |
| |
When the following test results are obtained,
the battery may be considered in good condition. The 5
|
| |
seconds voltage is over 9 volts for a 12volt
battery. It takes more down to 1 volt per cell. Cranking
ability |
| |
greatly depends on the 5 seconds voltage
because this voltage directly effects starter speed. |
| |
If a battery does not fulfil these conditions,
it should be considered faulty or of no further use. |
| |
|
| |
¢º Causes
of trouble |
| |
Battery trouble
may arise form the following causes: |
| |
a. Careless handling. |
| |
b. Faulty connections between battery and
related equipment (generator, regulator, starter etc).
|
| |
c. Improper storage |
| |
d. Unusual driving conditions. |
| |
e. Defects in battery materials and fabrication.
|
| |
f. Excessive electricity-consuming equipment.
|
| |
|
| |
¢º External
troubles of battery |
| |
Part in trouble
|
Type of trouble
|
Causes of trouble
|
Indications of trouble |
Container
|
Damaged container
|
careless handling
|
|
Distorted container
|
Charging with excessive current.
Too high ambient temperature
|
|
Cover
|
Damaged cover & plug
|
Careless handling
|
|
Terminal
|
Corroded
|
Insulfficient cleaning (current leak)
|
Thinned terminal |
Broken
|
Discharging with exvessive current
|
No condition
|
Containercover joint
|
Eletrolyte leakage through joint
|
Incomplete adhesion
|
|
|
| |
|
| |
Part
|
Indiction
of trouble
|
Type of
trouble
|
Cause of
trouble
|
Counter
measure
|
Decision
|
Container
|
Electrolyte leakage
|
* Cracked or broken
* Distorted container due to current too high ambient
temperature
|
Careless handling Charging with excessive
|
Replace the battery itself
|
X
|
Cover
|
|
* Damaged cover
* Damaged plug
|
Careless handling
|
|
X
|
Container- cover joint
|
Electrolyte leakage voltage drop
|
* Acid level of leakage cell is lower
than others.
* The wall between cells is adhesive.
|
Incomplete adhesion
|
Replace the battery itself
|
O
|
Terminal
|
Thinned terminal
|
* Corroded
|
insufficient cleaning
|
clean and grease them
|
X |
No conduction
|
* Broken
|
Discharging with excessive current
|
Replace the battery itself
|
X |
* Spark by loosent joint
|
Loosen joint between terminal an cable
terminal
|
Joint tightly
|
X |
* Internal curring incomplete welding
poor welding
|
Incomplete welding between bushing
and post.
|
Replace the battery itself
|
O
|
Element
|
* Plates arewhitened Sp.gr is lower
Voltage is lower during discharging Charging does
not restore battery
|
* Sulfation(plates are whitened due
to formation of lead sulfate)
|
* Over discharging
* Careless storge (without additional charging)
* Insufficient charging by generator
* Lack of electrolyte
|
Perform charging by lower rate during
the long time
|
X
|
Voltage : 0v, Abad (nasty)
smell.
|
*Constraction of negative plates
|
*Overdischarging
* Careless long storage
* Insufficient charging by generator
|
Additional charging
|
X
|
* Corrosion of Positive plate grid
|
* Over charging
* Too high sp.gr Charging and discharging at high
temperature
* Presense of impurites (hydro-chloric acid, nitric
acid, sea water,organic acid etc.)
|
Replace thebatteryitself
|
X
|
|
| |
|
Greetings from CEO
