ABOUT

Invented in 1859 by French physicist Gaston Planté, lead-acid batteries are the oldest type of rechargeable battery.

Planté began experiments that resulted in the construction of a battery for the storage of electrical energy. His first model contained two sheets of lead, separated by rubber strips, rolled into a spiral, and immersed in a solution containing about 10 percent sulfuric acid. A year later he presented a battery to the Academy of Sciences consisting of nine elements, housed in a protective box with the terminals connected in parallel. Remarkably, his battery delivered large currents.

WORKING

All lead-acid batteries consist of two flat plates—a positive plate covered with lead dioxide and a negative made of sponge lead—that are immersed in a pool of electrolyte (a combination of sulfuric acid (35%) and water solution (65%). Electrons are produced from the chemical reaction producing voltage. When there is a circuit between the positive and negative terminals, electricity begins to flow, providing connecting sources with power.

A lead-acid cell produces voltage by receiving a (forming) charge of at least 2.1 volts/cell from a charger. Known as Storage Batteries, lead-acid batteries do not generate voltage on their own/ they only store a charge from another source. The size of the battery plates and amount of electrolyte determines the amount of charge lead-acid batteries can store.

Storage capacity is described as the amp hour (AH) rating of a battery. In a typical lead-acid battery, the voltage is approximately 2 volts per cell, for a total of 12 volts or a rating of 125 AH, which equates to the battery's ability to supply 10 amps of current for 12.5 hours or 20 amps of current for a period of 6.25 hours.

Batteries are in a constant process of charge and discharge, discharging when connected to a load needing electricity such as a car starting and/or an accessory pulling a charge. A battery becomes charged when current flows back into it, restoring the chemical difference between the plates.

The lead plates become more chemically alike when a battery discharges, causing the acid to weaken and the voltage to drop. The battery will eventually become so discharged that it loses its ability to deliver useful voltage.

A battery, however, can be recharged by feeding it electrical current—restoring the chemical difference between the plates and returning the battery to full operational power.

Operational problems and failure have plagued lead-acid batteries since their invention more than 100 years ago. Through the years, science has improved materials, manufacturing methods and overall performance, however, the demand on lead-acid batteries continues to grow with a plethora of onboard gadgets drawing down on the power source, literally sapping batteries like a parasitic vampire. The lifespan of today's lead-acid battery typically ranges from as little a 6 months to 48 months—though only 30% survive the entire four years.

SULFATION

Lead-acid batteries are in a constant process of charge or discharge. If the battery is not being charged or maintained then it is discharging. In order to store energy within the battery, there are continuous chemical reactions occurring. This means that unused batteries also exhibit a slow discharge – even newly manufactured ones.

In theory, lead-acid batteries should last many years, but they usually don't because of a series of detrimental problems caused by excessive sulfation buildup related to the natural and necessary formation of sulfate crystals on the surface of lead battery plates. Over time as the battery is discharged, the electrolyte turns to water and the lead plates become covered with lead sulfate. This reaction is known as sulfation. If the battery is not being charged or maintained then it is discharging.

A lead sulfate is a crystalline material that starts as a small nucleus and enlarges over time into larger and larger crystal formations. These larger crystals have stronger bonds that require more energy to break. They form over longer periods of time. The longer the battery discharges, the stronger the bonds are that form and at some point it becomes impossible to remove the lead sulfate. At this point the battery is dead with no possibility of being recovered. In fact, 80% of the batteries in use worldwide 'die' prematurely due to this excessive sulfation buildup.

Pulse Technology has been scientifically proven to remove naturally occurring lead sulfates from the battery plates and return them to electrolyte solution. Used consistently, Pulse Technology will prevent the larger crystals from forming allowing more room in the battery to store energy which in turn allows the battery to accept, store and release maximum energy.

Types of LAB

Starting

These batteries start engines on cars, boats and other vehicles. They provide a short burst of strong power to get the engine started.

Deep Cycle

These batteries, used for industrial purposes, provide low, steady power over a period of time opposed to the instant burst of energy providing by starting battery types. The plates are much thicker and there is usually much more total energy available for a longer period of time.

Battery Construction Types

VRLA (Value Regulated Lead-Acid)

This type of battery is sealed and Maintenance Free. It uses special pressure valves and should never be opened. The valve(s) open when a preset pressure is realized inside the battery and lets the excess gas pressure out; the valve then resets itself. They are commonly composed of two types:

AGM (Absorbed Glass Mat)

AGM sealed battery technology was originally developed in 1985 or military aircraft. AGM technology has continued to develop and offer improvements over other sealed battery technologies. AGM is considered the next step in the evolution of both starting and deep cycle sealed batteries for marine, RV and aviation applications, delivering increased safety, performance, and service life over all other existing sealed battery types, including gel technology. In AGM sealed batteries, the acid is absorbed between the plates and immobilized by a very fine fiberglass mat. No silica gel is necessary. This glass mat absorbs and immobilizes the acid while still keeping the acid available to the plates. This allows a fast reaction between acid and plate material.

The AGM battery has an extremely low internal electrical resistance. This, combined with faster acid migration, allows the AGM batteries to deliver and absorb higher rates of amperage than other sealed batteries during discharging and charging. In addition, AGM technology batteries can be charged at normal lead-acid regulated charging voltages, therefore, it is not necessary to recalibrate charging systems or purchase special chargers.

Gel Cell

Gelled batteries or "Gel Cells" contain acid that has been "gelled" by the addition of Silica Gel, turning the acid into a solid mass thus making it impossible to spill acid even if they are broken. The recharge voltages on this type of cell are lower than the other styles of lead-acid battery to prevent excess gas from damaging the cells. This is not usually a problem with solar electric systems, but if an auxiliary generator or inverter bulk charger is used, current must be limited to the manufacturer's specifications. Gel batteries are best used in very deep cycle application and may last a bit longer in hot weather.

Wet Cell (flooded)

Most automotive batteries are wet cell, which operate by means of a liquid electrolyte solution. They come in two basic types—serviceable and maintenance free. The flooded battery typically delivers a peak current of 450 amps. An improved type of wet cell is the sealed valve regulated lead-acid (BRLA), which is popular in the automotive industry as a replacement for the lead-acid wet cell. The Valve Regulated Lead-acid (VRLA) battery uses an immobilized sulfuric acid electrolyte, reducing the chance of leakage and extending shelf life.

CARE-ROUTINE MAINTENANCE

There are eight major reasons for pre-mature battery failure:

Battery self-discharge
Key off parasitic drain
Insufficient run time
Corroded battery terminals and cables
Intermixing of un-matched batteries
Operator error
Faulty electrical systems
Physical damage

A battery that's at the end of its service life can't be recharged enough to restore it to a useful power level and must be replaced. However, a battery that has been attacked by microscopic sulfate crystals inhibiting the battery's ability to create, store and release energy, is a battery typically worth saving. It's common for people to assume a sulfated battery is 'dead' when it can't be recharged with a regular charger. However, battery recovery chargers using Pulse Technology have a 70%+ success rate of reviving these types of batteries.

GLOSSARY

State of Health

It means how much battery capacity is left (%) comparing with the marked original battery capacity

State of Charge

Is a measurement of voltage currently in the battery. It's usually stated as a percent of full charge.

CCA (Cold Cranking Amps)

This is the SAE (Society of Automotive Engineers) measurement that should be entered into the battery tester for test purposes. It is defined as the current in amperes which a new fully charged battery can deliver for 30 seconds continuously without the terminal voltage falling below 1.2 volts per cell, after it has been cooled to 0°F and held at that temperature. This rating reflects the ability of the battery to deliver engine-starting currents under winter conditions.

Ampere-Hour

The unit of measurement of electrical capacity. A current of one ampere for one hour implies the delivery or receipt of one ampere-hour of electricity. Current multiplied by time in hours equals ampere-hours.

SAFETY

Safety Basics

The electrolyte is a solution of sulfuric acid and water. This solution can cause chemical burns to the skin and especially the eyes.
During normal operation, water is lost from a non-sealed (or flooded) battery due to evaporation.
During charging, lead-acid batteries produce hydrogen and oxygen gases (highly flammable/explosive) as electrolysis occurs.
Many lead-acid explosions are believed to occur when electrolytes are below the plates in the battery and thus, allowing space for hydrogen/oxygen to accumulate. When the battery is engaged, it may create a spark the accumulated gases and causes the battery to explode.

Standard Precautions

Always store or recharge batteries in a well ventilated area away from sparks or open flames
Damaged lead-acid batteries should be kept in properly labeled acid-resistant secondary containment structures
Use only chargers that are designed for the battery being charged
Always keep lead-acid battery vent caps securely in place
Do not store acid in hot locations or in direct sunlight
Pour concentrated acid SLOWLY into water, do not add water into acid
Use non-metallic containers and funnels
If acid get into your eyes, flush immediately with water for 15 minutes, and then promptly seek medical attention
If acid gets on your skin, rinse the affected area immediately with large amounts of water. Seek medical attention if the chemical burns appear to be second degree or greater
Never overcharge a lead-acid battery and only replenish fluid with distilled water
Emergency was stations should be located near lead-acid battery storage and charging areas
Prevent open flames, sparks or electric arcs in charging areas
Lead-acid storage and charging areas should be posted with "Flammable- No Smoking" signs
Neutralize spilled or splashed sulfuric acid solution with a baking soda solution, and rinse the spill area with clean water

Servicing Recommendations

Keep metal tools and jewelry away from the battery
Inspect for defective cables, loose connections, corroded cable connectors or battery terminals, cracked cases or covers, loose hold-down clamps and deformed or loose terminal posts
Replace worn or unserviceable parts
Check the state of charge of non-sealed and sealed batteries with an accurate digital voltmeter when the engine is not running, and lights and other electrically powered equipment are turned off. Also check the electrolyte levels and specific gravity in each cell of non-sealed batteries
When checking the electrolyte liquid levels of the batteries use a rated flashlight that is intrinsically safe. In the event one is not available, use a plastic/non-metallic flashlight. Turn on the flashlight prior to getting near the battery when checking cell levels and turn off the flashlight when you are away from the batteries
Follow the battery manufacturer's recommendations about when to recharge or replace batteries
Tighten cable clamp nuts with proper size wrench. Avoid subjecting battery terminals to excessive twisting forces
Use a cable puller to remove a cable clamp from the battery terminal
Remove corrosion on the terminal posts, hold down tray and hold down parts
Use a tapered brush to clean battery terminals and the cable clamps
Wash and clean the battery, battery terminals, and case or tray with water. The corrosive acid can be neutralized by brushing on some baking soda (sodium bicarbonate) solution. If the solution does not bubble, the acid is probably neutralized
To prevent shocks, never touch or come in contact with both terminals at the same time. If baking soda solution is applied with a cloth, remember that these solution can conduct electricity
When battery cables are removed, ensure that they are clearly marked "positive" and "negative" so that they are reconnected with the correct polarity
Use a battery carrier to lift a battery, or place hands at opposite corners. Remember, batteries can weigh 30 to 60 pounds, so practice safe lifting and carrying procedures to prevent back injuries
Never fill battery cells about the level indicator
Do not squeeze the syringe so hard that the water splashes acid from the cell opening

LEAD-ACID BATTERIES

ABOUT

WORKING

SULFATION

Types of LAB

CARE-ROUTINE MAINTENANCE

GLOSSARY

SAFETY

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