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How to Prevent Early Damage to Lead-Acid Batteries
Release time:
2019-02-20
For a long time, both diesel and gasoline vehicles have relied on lead-acid batteries as their power source. When starting the engine, the battery needs to supply power to the starter motor within just a few seconds. If the battery malfunctions or suffers premature damage, it can disrupt the normal operation of the vehicle’s electrical system. Therefore, it’s crucial for us to identify the causes of premature battery failure and understand the precautions that should be taken during use. The fact that a battery fails to charge and discharge properly shortly after being put into service isn’t always due to battery quality issues alone. Batteries are most prone to premature damage when they’re improperly used or maintained. The main reasons for premature battery failure are as follows: 1. The battery is not securely fastened; driving...
For a long time, both diesel and gasoline vehicles have relied on lead-acid batteries as their power source. When starting the engine, the battery needs to supply power to the starter motor within just a few seconds. If the battery malfunctions or suffers premature damage, it can disrupt the normal operation of the vehicle’s electrical system. Therefore, it is crucial for us to identify the causes of premature battery failure and understand the precautions that should be taken during use. The fact that a battery fails to charge and discharge properly shortly after being put into service does not necessarily mean that the battery itself is defective. In most cases, improper use and maintenance are the primary factors leading to premature battery failure. The main reasons for premature battery damage are as follows:
1. The battery is not securely fastened, causing severe vibrations during driving, which lead to cracks in the sealing compound, fractures in the battery casing and lid, and breakage of the terminals and connecting plates.
2. If the battery terminals and clamps are installed too loosely or too tightly, installing them too tightly can lead to hammering the clamps during removal and installation, while installing them too loosely can cause poor contact and corrosion of the terminals.
3. Prolonged continuous use of the starter causes the battery to discharge rapidly, leading to bending of the plates and shedding of active material.
4. When the liquid level is too low, the portion of the plates exposed above the liquid surface comes into contact with air and undergoes intense oxidation. The oxidized part of the plates, in turn, comes into contact with the fluctuating electrolyte, gradually forming a hardened layer of coarse-grained lead sulfate and causing sulfation on the upper part of the plates. If the liquid level is too high, the electrolyte may splash out during vehicle operation, corroding mechanical components.
5. If a storage battery is consistently undercharged over a long period, the plates will become sulfated and unable to recover.
6. The generator regulator has failed, causing overcharging and rapid shedding of active material from the plates.
7. If impure distilled water is added to the electrolyte, or if metal containers are used when adding distilled water, impurities in the electrolyte can cause localized self-discharge, resulting in the battery’s inability to hold a charge.
8. In winter, if the battery is discharged and not recharged promptly, the electrolyte density may become too low and freeze, causing the active materials to fall off and shortening the battery’s service life.
To keep the battery in good condition at all times and extend its service life, it is essential to perform careful maintenance and master the correct usage methods. When using a battery, you must adhere to the following guidelines:
1. When installing the battery, do not tilt it beyond 40°. Before installation, check whether the battery has sufficient charge and ensure that no tools have been left on the battery. The battery must be installed securely, with good contact at the terminals. Do not apply excessive force to the terminal clamps when they are already tightened, as this could loosen the terminal posts and affect the power output. When replacing other electrical components, make sure to disconnect those components from the battery first.
2. The motor should not be run for too long; it is best to keep the running time under 5 seconds. Allow an interval of at least 30 seconds between two consecutive starts. If the motor fails to start successfully after three consecutive attempts, identify the cause, eliminate the fault, and then try starting it again.
3. Regularly check the electrolyte level. The electrolyte level should be 10–15 millimeters above the plates, or between the upper and lower liquid-level marks indicated on the battery case. A significant drop in the electrolyte level is usually due to water evaporation during battery operation. Therefore, when the electrolyte level is low, distilled water should be added. Only if it is confirmed that the level has dropped because of electrolyte spillage is it permissible to add electrolyte of the same density as the original solution. When checking the electrolyte level, never use any metal rods, as this could cause self-discharge.
4. Recharge the battery promptly: In summer, when the battery discharge reaches 50%, and in winter when it reaches 25%, remove the battery from the vehicle and give it a supplemental charge. Regularly check the condition of the generator regulator to prevent overcharging or undercharging.
5. The surface of the battery must be free of electrolyte and kept clean and dry. Dirt on the exterior can easily cause short circuits, leading to energy loss and battery damage. Oxide buildup between the terminal posts and wiring clamps can severely impede current flow, affecting the motor’s ability to start and the power supply to other equipment.
6. During winter use, the battery should be kept warm or equipped with a cold-weather cover; during summer use, avoid exposing it to direct sunlight.
7. Do not mix batteries from different manufacturers or batteries of varying ages and states of charge in the same battery pack, as this could lead to battery damage. It’s best not to charge batteries in parallel, as this could shorten their service life.
8. If batteries need to be stored, first fully charge them before disconnecting them from the charging device. Then, store the batteries in a cool, dry, well-ventilated, and clean location. Batteries that are left unused for extended periods should also be periodically recharged and maintained. All batteries experience internal self-discharge—typically about 2% per day. In other words, even if a fully charged battery is not used at all, its stored charge will eventually be completely drained by internal self-discharge over time. Moreover, a battery that has been discharged significantly will quickly suffer from plate sulfation, which severely reduces its ability to hold a charge. Therefore, batteries that are left unused for long periods should be given a top-up charge once a month, for about 10 hours each time. When batteries are rarely used, it’s essential to schedule monthly top-up charges to ensure they remain fully charged and ready for use.
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