Batteries Unlimited
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Solving Problems
Click on a link to see the solution.Nicad Battery Problems
Under charging of the whole battery
Possible Cause: Low float voltage/Charge current
Action: Adjust float voltage/charge current
Action: Adjust float voltage/charge current
Over charging of the whole battery
Possible Cause: High float voltage/Excessive periods of Boost charging
Action: Adjust float voltage/charge current. AVOID
Action: Adjust float voltage/charge current. AVOID
Low cell float voltages (all cells)
Possible Cause: Under charging
Action: See under charging of the whole battery
Action: See under charging of the whole battery
Low cell float voltages (individual cells
Possible Cause: Under charging
Action: Apply prolonged boost charge
Action: Apply prolonged boost charge
High cell float voltages
Possible Cause: Over charging
Action: See over charging of the whole battery
Action: See over charging of the whole battery
Cell voltages reversed polarity
Possible Cause: Over dis-charge
Action: Recharge battery
Action: Recharge battery
Specific gravity (SG) too low
Possible Cause: Dilution by topping up
Action: Adjust electrolyte
Action: Adjust electrolyte
Specific gravity (SG) too high
Possible Cause: Electrolyte incorrectly Prepared by manufacturer
Action: Seek manufacturer’s advice.
Action: Seek manufacturer’s advice.
Abnormal water consumption
Possible Cause: Over charging or high Temperature
Action: Adjust float voltage/charge current
Action: Adjust float voltage/charge current
Cell containers cracked
Possible Cause: Mechanical damage or possible internal gas explosion
Action: Adjust float voltage/charge current. Replace affected cells
Action: Adjust float voltage/charge current. Replace affected cells
Corrosion of inter-cell connectors, or terminals
Possible Cause: Spilled electrolyte or ineffective protective Greasing
Action: Remove nuts & bolts clean and regrease, if parts are Damaged…replace
Action: Remove nuts & bolts clean and regrease, if parts are Damaged…replace
Corrosion of battery stand/cubicle
Possible Cause: Spilled electrolyte or over Charging
Action: Replace stand/cubicle if structural integrity impaired. Otherwise clean and protect
Action: Replace stand/cubicle if structural integrity impaired. Otherwise clean and protect
Loose nut terminal/inter-cell Connections
Possible Cause: inappropriate torque setting used when Tightening nuts/bolts or Loosening over time.
Action: Tighten using the correct torque settings
Action: Tighten using the correct torque settings
Unequal state of charge of cells
Possible Cause: Prolonged float charging @ 1.40 to 1.42 per cell Without boost charging
Action: Boost charge to equalise state of charge
Action: Boost charge to equalise state of charge
Lead Acid battery Problems
Under charging of the whole battery
Possible Cause: Low float voltage/Charge current
Action: Adjust float voltage/Charge current Accurately
Action: Adjust float voltage/Charge current Accurately
Over charging of the whole battery
Possible Cause: High float voltage/ Change current Excessive periods of Boost charging
Action: Adjust float voltage/ charge current accurately AVOID
Action: Adjust float voltage/ charge current accurately AVOID
Low specific gravity (all cells)
Possible Cause: Under charging
Action: see under charging of the whole battery
Action: see under charging of the whole battery
Low specific gravity (odd cells)
Possible Cause: Under charging due to Higher charge current Requirement due to :- Internal short-circuits Electrolyte contamination
Action: If shorts present remove shorts or replace cell. If negative plates are Reddish colour indicates Copper contamination. Replace affected cells.
Action: If shorts present remove shorts or replace cell. If negative plates are Reddish colour indicates Copper contamination. Replace affected cells.
Irregular specific gravity between Cells.
Possible Cause: Under Charging
Action: see under charging of the whole battery
Action: see under charging of the whole battery
High specific gravity (all cells)
Possible Cause: Low electrolite levels due To over charging or recent Electrolyte change
Action: See over charging of the whole battery. If recent electrolyte Change then refer to Manufacturer guide on SG adjustment
Action: See over charging of the whole battery. If recent electrolyte Change then refer to Manufacturer guide on SG adjustment
Low cell float voltage (all cells)
Possible Cause: Under charging
Action: See under charging of The whole battery
Action: See under charging of The whole battery
Low cell float voltage (odd cells)
Possible Cause: Under charging due to higher charge current Requirement due to - Internal short circuit, Electrolyte contamination (chlorine) incorrect cell polarity.
Action: See low specific gravity (odd cells) if polarity incorrect replace cell.
Action: See low specific gravity (odd cells) if polarity incorrect replace cell.
Excessive water consumption Electrolyte topping up requirement More often than yearly.
Possible Cause: Over charging or general deterioration
Action: see over charging of the whole battery. If Excess water loss due To general deterioration consider battery Replacement.
Action: see over charging of the whole battery. If Excess water loss due To general deterioration consider battery Replacement.
Peroxidation (black positive pillar)
Possible Cause: Acid creeps due to poor seals
Action: Remove peroxidation. Fit new seal, Regrease.
Action: Remove peroxidation. Fit new seal, Regrease.
Corrosion of battery stand/cubicle.
Possible Cause: Spilled electrolyte
Action: Replace stand/cubicle if Structural integrity impaired.
Action: Replace stand/cubicle if Structural integrity impaired.
Positive plates light brown negative Plates dark grey
Possible Cause: under charging
Action: see under charging of the whole battery.
Action: see under charging of the whole battery.
Cell sediment near or touching plates
Possible Cause: Normal ageing process
Action: Replace battery. Also see internal short- circuit.
Action: Replace battery. Also see internal short- circuit.
Dropped positive plate
Possible Cause: Excessive corrosion at Group bar to plate interface.
Action: Replace battery
Action: Replace battery
Expansion of positive plates
Possible Cause: Normal ageing process
Action: Determine if battery Serviceable if expansion Causing pressure on cell Containers or lids to lift Or twisting of group Bars replace battery.
Action: Determine if battery Serviceable if expansion Causing pressure on cell Containers or lids to lift Or twisting of group Bars replace battery.
Cell Lids/containers cracked.
Possible Cause: Result of ageing process Due to excess or positive Pillar corrosion or Mechanical damage.
Action: if due to age, replace battery. See positive pillar corrosion.
Action: if due to age, replace battery. See positive pillar corrosion.
Positive pillar corrosion
Possible Cause: Acid path between pillar And ill fitting seal causing Acid trap against pillar.
Action: Replace affected cells
Action: Replace affected cells
Copper insert corrosion (corroded pillar insert causing Loss of integrity and by visible Copper deposit on plates and in And in sediment space)
Possible Cause: Manufacturing defect causing passage of electrolyte through lead part of pillar to copper insert
Action: Replace affected cells
Action: Replace affected cells
Corrosion of inter-cell connector Nuts & bolts.
Possible Cause: Spilled, electrolite, ineffective Protective greasing or acid Creep.
Action: If current carrying capability is impaired, Replace affected parts. Otherwise clean, re-Apply correct torque Settings and regrease
Action: If current carrying capability is impaired, Replace affected parts. Otherwise clean, re-Apply correct torque Settings and regrease
White pock marks on the weakest Positive plates plus white salt deposit In sediment space.
Possible Cause: AC corrosion due to high ripple current from charger Output. May be defective rectifier.
Action: Investigate and seek manufacturers advice.
Action: Investigate and seek manufacturers advice.
Horizontal white ring around the Plates
Possible Cause: Low electrolyte levels allowing plates to dry out.
Action: Replace cells affected.
Action: Replace cells affected.
Negative plates reddish colour
Possible Cause: Copper contamination due to Topping up with the tap water Or other inappropriate water
Action: Replace cells affected
Action: Replace cells affected
Bleaching out separators
Possible Cause: Chlorine/fluoride contamination Due to topping up with tap water Or other inappropriate water
Action: Replace cells affected
Action: Replace cells affected
Internal Short circuit
Possible Cause: Positive group bar scale shorts Between plates or cell Sediment touching the bottom Of the plates.
Action: If scale shorts, remove shorts or replace cell.
Action: If scale shorts, remove shorts or replace cell.
Loose nut/bolt/connector
Possible Cause: Inappropriate torque setting used or loosening over time
Action: Tighten to manufacturer Torque settings.
Action: Tighten to manufacturer Torque settings.
