Battery System -TESTING Battery, BatteryTesting

BATTERY SYSTEM —TESTING BATTERY

BatteryTesting

Before conducting any battery tests, refer to page 11 for battery safety instructions.

Low water-loss batteries of the latest design may incorporate flame-arrester vents to reduce the possibility of explosions caused by external sparks. Therefore, during charging and testing, the flame-arrester vents should remain in place.

Refer to Figure 18, Battery Testing Chart on page 55.

Step One (1) -Visual Inspection (See Flow Chart, Figure 18 on next page)

a.Visually inspect the battery for container, cover, or terminal damage that may have caused leakage of electrolyte or internal damage. If damage is found, replace the battery.

b.Check the condition and the size of the battery cables. Check for corrosion on the battery terminals and cable terminations. Corrosion on side terminal batteries may not be evident until the cables have been removed. Replace badly corroded cables or cables with defective terminations. Make certain the ground cable is making a good connection where it is grounded. Check the connection of the cable to the starter relay or solenoid. Proceed to step two.

Step Two (2) - Electrolyte Levels and State of Charge

Although these batteries are designed to preclude adding water, the volume of reserve electrolyte above the plates may eventually be depleted. In most cases, this will signal the end of the battery's useful life. Since many have sealed covers in place of filler caps, it may not be possible to check the electrolyte levels by looking directly into the cells. However, many low water loss batteries are contained in translucent plastic cases which may allow electrolyte levels to be seen. Other models utilize built-in hydrometers which also serve as electrolyte level indicators. If electrolyte levels can be seen and found to be low, check for a charging system malfunction.

If the electrolyte level is below the top of the plates in any cell, and if vents are removable, add water before proceeding further. If water cannot be added, replace the battery.

The battery must be at an adequate state of charge in order for the following load test to be valid. If the battery does not contain a built-in hydrometer, the state-of charge can be estimated with an accurate voltmeter.

a.If the stabilized open circuit voltage is below 12.4 volts, charge the battery (or check battery charger connection). A stabilized voltage reading is assumed after the battery has remained on open circuit for a minimum of 4 hours or, preferably, overnight. When a hydrometer reading can be taken, a value of 1.225 @ 80°F (26.7°C) can be used instead of the 12.4 voltage reading. If the battery has a built-in hydrometer, follow the instructions of the manufacturer. After the battery is charged, proceed to step 2.c.

b.If the state-of-charge of a battery cannot be determined, it must be charged. After the battery is charge, proceed to step 2.c.

c.Remove surface charge by attaching load test leads to the terminals and applying a load equal to 1/2 of the cold cranking amps at 0°F (-17.8°C) rating of the battery for 15 seconds. Manufacturers may prescribe specific methods. Follow specific instructions when they are available. Proceed to step 3.

d.If the stabilized voltage of the battery was 12.4 or above when it was first examined, or the built-in hydrometer indicated the battery was charge, proceed to step 3.

Step Three (3) - Load Procedure

The load test is conducted to determine if the battery has adequate electrical performance or if it has to be replaced. This procedure is valid only if the battery is at or above the state of charge specified in step 2.

a.Connect the voltmeter and load test leads to the battery terminals; be sure the load switch is in the "Off" position Proceed to step 3.b.

b.Apply a load test equal to 1/2 of the cold cranking rating of the battery at 0°F (-17.8°C). Read voltage after fifteen (15) seconds with the load connected. Remove load. Estimate or measure the battery temperature and compare voltage reading with the voltage chart (see Figure 17 on page 53). If the voltage is less than the minimum specified, replace the battery. If the voltage meets or exceeds the specified minimum, return the battery to service.

PAGE 54 — INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07)