How to maintain lead-acid batteries

Sulfation accounts for 80% of breakdowns and capacity loss in lead-acid batteries. However, with the right tools and a little time, starter batteries, semi-traction batteries, traction batteries and even stationary batteries can be revived and continue to function reliably. In this blog, the Energic Plus experts outline three essential maintenance tasks that will optimise the performance of lead-acid batteries.

Replace the electrolyte

The fluid in a lead-acid battery, the electrolyte, consists of a mixture of sulphuric acid and water. When the battery is charged, the electrolyte heats up. This causes some of the water to evaporate through electrolysis, whereby the water breaks down into hydrogen and oxygen gases that then dissipate. Consequently, the electrolyte level in the battery decreases over time. If the level gets too low, the sulphuric acid becomes more concentrated, and the plates in the battery cells become exposed and damaged. This is why the electrolyte needs to be replaced regularly. Here are some things to take into account:

Check the water level
Although you can manually check the battery to determine when to add water, there are easier and less time-consuming alternatives. Indicators, for example, can be mounted behind the battery plug and notify you when the battery needs to be topped up.
Only use distilled water
Never fill a battery with tap water, as this will damage it. Instead, use distilled water, also known as deionised or demineralised water, which has been filtered to remove the metals and minerals that can interfere with the battery’s processes.
Install an automatic battery water filler system
The amount of distilled water required to top up a battery can vary, which is why using a battery water filler system is recommended. This system utilises filler caps with floats that are connected to each other via water hoses, preventing the battery from overfilling. All you need to do is run distilled water into the hose; the filling system takes care of the rest.
Beware when charging
Before charging the battery, always ensure that the electrolyte covers the battery plates. If they are covered, charge the battery and then top it up as necessary. This is because the electrolyte expands during charging and is more likely to overflow if topped up beforehand.

Lead-acid battery equalisation

The more a battery is charged, the greater the fluctuation in cell capacity may be. For example, one cell might be fully charged while another is only half-charged. If this happens, the battery will not charge fully.

To ensure an even charge, it’s best to perform an equalisation charge. During this process, the charger delivers a lower current over a longer period. While a typical charging cycle lasts around eight hours, equalisation takes about eleven hours. Since equalisation also requires longer cooling times than regular charging, it’s best done at the weekend, allowing enough time for both charging and cooling before the battery is used again.

Even if the battery is already affected by sulfation, it is possible to control and reduce it through equalisation. Simply send large currents of short duration through the battery. This process is known as battery reconditioning.

Keep the battery clean

Leakage currents caused by battery acid, dirt and dust can make a battery discharge itself and become unbalanced. Therefore, it is essential to keep batteries clean and free from debris. Various products are available to help with cleaning batteries, such as battery steam cleaners.

Find out even more about Energic Plus

Read some of our other blogs to find out more about industrial batteries, chargers, and advanced battery maintenance solutions from Energic Plus:

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About the authors

This blog post is brought to you by your Energic Plus team.

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