Don’t let a dead battery bring production to a halt at your job site. Take time to learn more about why batteries fail prematurely and what you can do to maximize battery life. The more you know about the subject, the better you’ll be able to choose a battery that delivers reliable performance, long life, and lower owning and operating costs.
VIBRATION
Excess vibration is the number-one cause of battery failure in off-highway equipment. Whether you’re digging a basement, hauling rock or loading a fleet of trucks, your machines and vehicles take a beating all shift long. And …so do the batteries. When a battery is subjected to constant vibration, the active material can separate from the plates. This reduces electrical storage capacity, making it harder to start the engine. As the active material sheds and falls into the bottom of the case, it can build up to a level that causes a short. In some situations, an entire plate can break free, drop into the case and short out a cell. Vibration can also crack or break the straps that hold the plates together, resulting in a lost cell and a catastrophic failure. And if rocks or debris get trapped underneath a battery, excess vibration can cause the material to wear through the case, leading to a loss of electrolyte.
Given the punishing conditions in which you work, it’s critical to equip your machine or vehicle with a premium-quality battery—one that’s designed for maximum resistance to vibration and long, trouble-free life. All batteries must meet a minimum specification for vibration resistance, but some brands are subjected to much more aggressive vibration testing than others. Look for a battery that exceeds industry vibration standards. Choose one with heavy-duty cast-on straps and full-frame, heavy-duty plates. Make sure both the positive and negative plates are anchored to the container bottom, and the cell element is locked at the top for maximum vibration resistance.
HEAT
Extreme heat is another big culprit when it comes to premature battery failure. Batteries exposed to very high operating temperatures lose performance and experience a reduction in service life. As a rule of thumb, service life for all types of lead acid batteries is reduced by 50 percent for every 15° F (9.4° C) over 77° F (25° C).
To get maximum performance and life from your battery, under-the-hood temperatures should not exceed 126° F (52° C) during normal use. Storage temperature should not exceed 80° F (27°C), as batteries self-discharge quickly when stored in hot places.
OVERCHARGING OR UNDERCHARGING
When batteries are overcharged on a regular basis, water boils out of the electrolyte, the plates warp from overheating and the positive plates corrode at an accelerated rate, causing plate-to-strap shorts. Overcharging can also cause excessive gassing and deterioration of the lead grid and internal paths.
Undercharging isn’t good for a battery either. Operating a battery with a consistent charge deficit leads to permanent plate sulfating and acid stratification, both of which reduce the battery’s storage capacity and service life.
Maintaining the correct voltage regulator setting is key to achieving optimal performance and life. The correct setting is defined as one that keeps the battery fully charged with minimum water usage under a wide variety of operating conditions.
When batteries are overcharged on a regular basis, water boils out of the electrolyte, the plates warp from overheating and the positive plates corrode at an accelerated rate, causing plate-to-strap shorts. Overcharging can also cause excessive gassing and deterioration of the lead grid and internal paths.
Undercharging isn’t good for a battery either. Operating a battery with a consistent charge deficit leads to permanent plate sulfating and acid stratification, both of which reduce the battery’s storage capacity and service life.
Maintaining the correct voltage regulator setting is key to achieving optimal performance and life. The correct setting is defined as one that keeps the battery fully charged with minimum water usage under a wide variety of operating conditions.
DEEP CYCLING
A deep cycle occurs when you start with a fully charged battery, use 80 percent or more of its rated capacity, then recharge it fully. All batteries are manufactured to withstand a limited number of deep cycles, so if you deep cycle on a daily basis, you’ll reduce service life significantly.
To maximize life, use just 25 to 50 percent of rated capacity before recharging. If your job requirements demand daily deep cycling, select a battery designed for that application.
MISAPPLICATION
Battery performance and life decline when you choose the wrong battery for your application. Don’t buy an undersized battery that causes discharges greater than 10 percent, or one with a Cold Cranking Amp rating that’s lower than the manufacturer’s recommendation. For best results, consult with your product support provider to select a replacement battery that meets meet your performance and life expectations.
OTHER FACTORS
Some of the many other factors that reduce battery life or cause premature failure include the following:
Using tap water rather than distilled water
Subjecting a battery, particularly a discharged one, to freezing temperatures
A faulty alternator or voltage regulator
A short in the wiring system
Failure to disconnect the battery when the machine or vehicle will be sitting for a long period of time.
Excessive electrical options on a machine or vehicle.
TAKING CHARGE
No battery lasts forever, but there are three things you can do to get the longest possible life from yours.
Be an educated buyer. Don’t be fooled by low-priced alternatives. Invest in a rugged, reliable battery—one that delivers maximum Cold Cranking Amps, exceeds the minimum industry standard for vibration resistance and withstands the punishing environment in which you work.
Operate within the proper charge and discharge voltages. Use a charge controller circuit to prevent battery overcharge and a Low Voltage Disconnect (LVD) circuit to reduce excessive battery discharge.
Follow maintenance and storage recommendations. Include the battery in your normal maintenance schedule. Perform a thorough visual inspection, checking for cracks and removing dirt and debris. Be sure the vent caps are in place, and confirm that terminal connections and hold-downs are torqued properly. Tighten alternator belts and check the alternator output voltage with a voltmeter. If your machine or vehicle will sit idle for an extended period of time, disconnect the battery or remove and store it a cool, dry place where temperatures do not fall below 32° F (0° C) or exceed 80° F (27° C).
WANT TO LEARN MORE?
If you have questions about any aspect of battery design, testing, performance or service life, contact your Stowers Product Support Sales Representative. The more you know about the subject, the better you’ll be able to choose a battery that delivers reliable performance, long life and low owning and operating costs.
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