Technical manual section 00

Battery Council International expressly denies any warranties or guarantees, express or implied, in connection with the information in this manual.. INTRODUCTION This technical manual w

Technical

06

Current Revision: 2006-04

BCI TECHNICAL MANUAL INTRODUCTORY MATERIAL

1 DISCLAIMER STATEMENT

Battery Council International publishes technical information in this manual as an aid to its members and to the public The information in this manual is based on sound engineering principles, research, extensive field experience and technical judgments of industry members, and is subject to change in light of developments in technology and field experience Use or adoption of the information contained in this manual is

voluntary Battery Council International expressly denies any warranties or guarantees, express or implied, in connection with the information in this manual

2 INTRODUCTION

This technical manual was prepared for all users of automotive and industrial type lead acid batteries with specific reference to laboratory analyses and test methods for evaluation of battery performance, major component parts and raw materials used to manufacture these batteries

Industry technical personnel who are members of the BCI Technical, Industrial Battery and Charger, Deep Cycle and Electric Vehicle Battery and/or Product Safety

Committees wrote all BCI outlined test procedures They are intended to provide a common means for the manufacturer and his customer to describe and compare desired battery performance They apply in total to batteries manufactured for the lead-acid battery aftermarket

Those specifications, tests, and procedures outlined under the ‘SAE’ heading are those which represent batteries manufactured for Original Equipment (OE) purposes and are a result of the report of the Electrical Equipment Division approved January 1914 The revisions as prepared by the SAE Storage Battery Subcommittee approved by the Electrical Equipment Committee, June 1993, with subsequent revision when published

To each and every individual who contributed to this second edition, we extend our sincere appreciation Special thanks go to Conrad E Weinlein for his efforts in seeing this edition through to completion

3 SAFETY FIRST

3.2 Danger of Exploding Batteries

Batteries contain sulfuric acid and they produce explosive mixtures of hydrogen and oxygen Because self-discharge action generates hydrogen gas even when the battery

is not in operation make sure batteries are stored and worked on in a well-ventilated area ALWAYS wear safety glasses and a face shield when working on or near

batteries When working with batteries:

3.2.1 Always wear proper eye, face and hand protection

3.2.2 Keep all sparks, flames and cigarettes away from the battery

3.2.3 Do not remove or damage vent caps

3.2.4 Cover vent caps with a damp cloth to minimize gas seepage

3.2.5 Make sure work area is well ventilated

3.2.6 Never lean over battery while boosting, testing or charging

3.3 Safe Battery Installation

To assure safe installation and proper operation, follow these installation procedures: 3.3.1 Disconnect ground cable first (this is usually the negative cable, however, older vehicles

may have a positive ground)

3.3.2 Remove old battery – note position of positive (+) terminal and negative (-) terminal

Mark the cables for correct connection to new battery

3.3.3 Clean terminals and cable connections with a wire brush Broken connections or frayed

or cut cables should be replaced

3.3.4 Install the new battery in the same position as the old one, be sure to secure it with the

hold-down assembly

3.3.5 Make sure battery terminals do no touch any metal mounting, engine or body parts 3.3.6 Connect cables tightly Connect ground cable last to avoid sparks

3.4 Safe Charging

Before beginning the charging operation, read the instructions that come with the charger Never attempt to charge a battery without first reviewing the instructions for the charger being used In addition to the charger manufacturer’s instructions, these general precautions should be followed:

3.4.1 Always charge batteries in a well-ventilated area and wear proper eye protection 3.4.2 Turn the charger and timer “OFF” before connecting the leads to the battery to avoid

dangerous sparks

3.4.3 Never try to charge a visibly damaged or frozen battery

3.4.4 Connect the charger leads to the battery; red positive (+) lead to the positive (+) terminal

and black negative (-) lead to the negative (-) terminal If the battery is still in the vehicle, connect the negative lead to the engine block to serve as a ground (If the vehicle is positive grounded, connect the positive lead to the engine block.)

3.4.5 Make certain that the leads to the connections are tight

3.4.6 Set the timer, turn the charger on and slowly increase the charger rate until the desired

ampere value is reached

3.4.7 If the battery becomes hot or if violent gassing or spewing of electrolyte occurs, reduce

the charging rate or temporarily halt the charger

3.4.8 Always turn the charger “OFF” before removing charger leads from the battery to avoid

dangerous sparks

3.5 Handling Battery Acid

Battery acid, or electrolyte, is a solution of sulfuric acid and water that can destroy clothing and burn the skin Use extreme caution when handling electrolyte and keep an acid neutralizing solution – such as baking soda or household ammonia mixed with water – readily available In the event of a spill:

3.5.1 Always wear proper eye protection

3.5.2 If electrolyte is splashed into the eye, immediately force the eye open and flood it with

clean cool water Get prompt medical attention

3.5.3 If electrolyte is taken internally, drink large quantities of water or milk DO NOT induce

vomiting Call a physician immediately

3.5.4 Neutralize with baking soda any electrolyte that spills on a vehicle or in the work area,

rinse contaminated area with clean water

To prepare electrolyte of a certain specific gravity, always pour the concentrated acid slowly into the water; DO NOT pour water into the acid Always stir the water while adding small amounts of acid If noticeable heat develops, allow the solution to cool before continuing to add acid

3.6 Safe Booster Cable Operation

When jump starting, always wear proper eye protection and never lean over battery Do not jump start a damaged battery Inspect both batteries before connecting booster cables Be sure vent caps are tight and level, place a damp cloth over the vent caps of both batteries Make certain that the vehicles are not touching and both ignition switches are turned to the “OFF” position:

3.6.1 Connect positive (+) booster cable to positive (+) terminal of discharged battery

3.6.2 Connect other end of positive (+) cable to positive (+) terminal of assisting battery 3.6.3 Connect negative (-) cable to negative (-) terminal of assisting battery

3.6.4 MAKE FINAL CONNECTION OF NEGATIVE (-) CABLE TO ENGINE BLOCK OF

STALLED VEHICLE, AWAY FROM BATTERY

3.6.5 Start vehicle and remove cables in REVERSE order of connections