Untitled Document

BATTERY CARE

CLEANLINESS

A dirty battery tends to hold spilt electrolyte on the external surface, providing a conductor for electrical current which leaks to earth, discharges the battery and causes the terminal clamp and nearby metalwork to corrode. Therefore, it is essential to keep the outside surfaces of a battery free from contamination.

Corrosion will cause a high resistance at connections and although corrosion between terminal posts and clamps may still allow sufficient current to pass to light lamps etc., it may not start the engine. In overcoming this problem clean connecting surfaces lightly with a fine abrasive and smear them with petroleum jelly before fitting.

ELECTROLYTE

The electrolyte level in the battery is very important. If too high, expansion due to increases in temperature and the collection of gas bubbles on the plates during charging may cause overflowing.

Spilt electrolyte provides a conduction path to earth and may allow the battery to discharge resulting in a flat battery. Spilt electrolyte may be removed with large quantities of water or by the use of a weak alkaline solution such as washing soda. (Dissolve 100g in 1 litre of water).

If the electrolyte level is too low the plates are exposed to the air and permanent damage and loss of capacity may result. Vent caps should remain in position during charging to minimise the spray of electrolyte caused by gassing.

The level of electrolyte should be maintained as follows:

Water only is lost from a battery during normal service therefore topping up should be carried out using approved battery water. The use of water other than approved battery water may lead to contamination of electrolyte. This contamination would be cumulative resulting in permanent damage to the battery.

Electrolyte should be maintained at 10 mm above plates unless otherwise specified on the battery. Acid should not be added to a battery unless some acid has been spilt or lost. Should it be necessary to add acid ensure that the specific gravity matches each cell to which it is added.

A battery that has become contaminated should be thoroughly flushed out with approved water, refilled with electrolyte, fully charged and then the specific gravity adjusted in each cell.

SULPHATION

In the normal operation of a battery the plates are converted to lead sulphate each time it is discharged. The sulphate takes the form of fine crystals which are easily and completely dissipated on recharging.

However, should the plates be allowed to remain in the sulphated condition for a long period, the "temporary sulphate" may be converted to "permanent sulphate" and become impossible to remove. The formation of permanent sulphate is accompanied by the growth of large crystals leading to uneven expansion of the plates and eventual buckling.

Short circuits may result if the buckling causes wear and penetration of the separators.

"Permanent" Sulphation is caused by: Operating a battery in a low state of charge for lengthy periods. Allowing a battery to stand in a discharged state for a long period. Leaving a charged battery for long periods without regular recharges.

Possible Remedy: A sulphated battery may recover by charging at 1 amp for seven days or until specific gravities of the electrolyte have reached maximum and constant values. This state, then indicates the limit of recovery.

Note:
No benefit will be derived from the use of additives of dopes which neither prevent nor cure sulphation.

Insufficient charging will cause permanent sulphation because the temporary sulphate is not completely removed from the plates during recharging allowing the remainder to convert to permanent sulphate. (See Sulphation).

A BATTERY LEFT IDLE

A battery left idle in a discharged state for a lengthy period encourages the formation of permanent sulphate and accompanying damage to the plates.

If a battery is to be taken out of service and left idle, the electrolyte must be maintained at the correct level and it should be fully charged at a low rate once a month.

HIGH SPECIFIC GRAVITY

If the specific gravity of the electrolyte exceeds 1.260 for automotive batteries used in temperate or tropical climates, it will result in increased chemical reaction causing deterioration of the plates and separators and shortening the life of the battery.

OVERCHARGING

Overcharging is charging beyond the time necessary to fully charge the battery or conducted at an excessive rate in amps for the particular battery. It produces erosion and corrosion of the positive material and causes the grids to fracture reducing their ability to carry the starting current.

Overcharging is usually accompanied by heavy gassing which will accelerate the shedding of the active material from the positive plates. Excessive deposition of active material in the bottom of the battery container will cause a build up of silt which may bridge the plates and cause internal short circuits.

Overcharging is usually accompanied by high electrolyte temperatures resulting in rapid deterioration of the plates and separators. Overcharging may cause buckling of the plates leading to perforation of the separators and internal short circuits.

BATTERY HAZARDS

When being charged, or even when on standby, batteries may contain hydrogen gas and air in an explosive mixture. This gas may be ignited by a naked light such as matches, cigarette lighters, sparks from short circuits caused by spanners or incorrectly connecting jumper leads. Disconnect the earth lead first and replace it last when removing or replacing batteries. This will minimise the risk of a short circuit between tools and vehicle frame.

Always switch off all vehicle electrical equipment or charging equipment, when in use, before removing the vehicle of charger leads. This will minimise the possibility of sparks. Battery electrolyte contains sulphuric acid which may cause damage to eyes, skin or clothes if spilt or splashed.
Flush the eyes with running or large volumes of water, wash or hose off splashes with water. Washing soda and water may be used to neutralise electrolyte in inaccessible or dead end space on the vehicle.

HOW TO HANDLE AN ACID SPILL
In the event of a spill during transportation:

1.	Do not wash the acid away with water.
2.	Do not allow the acid to enter drains.
3.	Stop vehicle engine.
4.	No naked lights.
5.	No smoking.
6.	Erect the self-standing warning signs.
7.	Keep public away.
8.	Immediately inform Battery Centre management (who can call the local Fire Department to assist)
9.	Wear the correct P.P.E. (Personal protective equipment) i.e. goggles or face shield, acid proof apron, acid proof gloves.
10.	Stop leaks.
11.	Cover the spilled acid with soda ash or sand or make dams to contain the acid.
12.	Sweep or shovel thesoda ash up to clean up the acid.
13.	Place soda ash or sand intoa receptacle, bag or box and take back to Battery Centre.
14.	Send the acid contaminated soda ash or sand to First National Battery, Benoni or East London, marked correctly "Acid Contaminated Soda Ash".
15.	Inform the Loss Control Office or Plant Engineer that you have sent it.

In the event of a spill at Battery Centre

1.	Wear the correct P.P.E. (Personal protective equipment) i.e. i.e. goggles or face shield, acid proof apron, acid proof gloves.
2.	Stop the leak, pick up batteries etc.
3.	Spread soda ash over the spill.
4.	Do not wash the acid away with water.
5.	Do not alliow acid to enter drains.
6.	Allow soda ash to absorb and neutralise the acid.
7.	Sweep up the soda ash and place in a bag or container.
8.	Send acid contaminated soda ash to First National Battery Benoni or East London, marked correctly "Acid Contaminated Soda Ash".
9.	Inform the Loss Control Office or Plant Engineer that you have sent it.

TRANSPORTING ACID
Acid may be transported in batteries (new and scrap) and in polycans provided that:

1	The acid content of the batteries, new or scrap, does not exceed 200kg.
2	The acid content of the polycans does not exceed 50kg. (One polycan = 28kg)

If these amounts are exceeded, Chapter VIII of the Road Traffic Act comes into force. Similarly if you use a vehicle of 2300kg or more the above legislation applies. If you require more information, then contact Dave Gassner, as it gets a bit complicated. For bakkies and small trucks it would be advisable to equip them with a fire extinguisher and a small spill kit to handle small emergencies. Note that in more centre the Fire Department will assist and probably charge you. If there is any spillage on a bakkie it is better to use some soda ash to soak it up rather than have the acid blowing off onto somebody's car or it is spills on the road you don't want cars driving through the acid. You can get copies of the Tremcard (Transport emergency card), required for transporting acid inexcess of the exempted quantities, from Dave gassner for guidance on action required for spills from vehicles. Legally, each workplace that works with chemicals must display the MSDS (material safety data sheet) for the chemical and train all employees on the correct use of the chemical. You can find the MSDS for battery acid on www.battery.co.za in the downloads section.
Back