Service Handbook

Battery Technology

5.905-332
11.98
Foreword Battery Technology

Foreword

Good servicing requires extensive and relevant training, as well as comprehensible reference
documents.

We therefore regularly offer all service technicians both basic and ongoing training courses for the
full range of our products.

In addition we produce service handbooks for major equipment which can be used initially as
instructional material and subsequently as sources of reference.

Furthermore we regularly distribute service information bulletins that provide details about further
developments to the products.

Sources:
Information from the firms Hagen, Sonnenschein and DETA has also been included in this service
manual.

Copying and duplicating texts and illustrations, or passing the contents on to a third party, requires
the express permission of:

ALFRED KÄRCHER GmbH & Co.

CUSTOMER SERVICE TRAINING
PO Box 160
D-71349 Winnenden

2
Battery Technology Table of contents

Table of contents
Types of battery .................................................................................... 4
Safety information ................................................................................ 4
Battery construction ............................................................................. 5
Electrochemical process in a low-maintenance battery .................... 6
Electrochemical process in a maintenance-free battery .................... 8
Charging technology and characteristic curves ............................... 10
Charging technology and characteristic curves
for low-maintenance batteries ........................................................... 11
Charging technology and characteristic curves
for maintenance-free batteries ........................................................... 12
Information about battery charging ................................................... 13
Voltage curve during one complete discharge/charge cycle
for two battery blocks connected in series ....................................... 14
State of charge of a low-maintenance battery .................................. 15
State of charge of a maintenance-free battery .................................. 16
Operating modes ................................................................................ 17
Operational capacity........................................................................... 19
Nominal capacity ................................................................................ 20
Service life........................................................................................... 21
Care and maintenance........................................................................ 23
Battery diagnostics (low-maintenance) ............................................. 25
Battery diagnostics (maintenance-free) ............................................ 29
Batteries and battery chargers for sweepers .................................... 32
Batteries and battery chargers for floor scrubbers .......................... 33
Diagnostic Report for complaints about batteries ........................... 34
Keywords and definitions ................................................................... 47

3
 Battery Technology

Types of battery Safety information

– Fixed-installation batteries that must be observed when handling batteries:
for back-up power supply in control and
Observe details contained in user
switching systems, telecommunications,
instructions, and display these instruc-
signal and flashing-light installations, test
tions prominently at location where
and measurement facilities, hospitals, atomic
charging is carried out. Work on
research centres, power stations, pumping
batteries should only be undertaken
and other industrial plants.
after suitable instruction has been
– Traction batteries received from a qualified person!
for industrial trucks, electric vehicles, tractors,
Wear safety goggles and protective
sweepers, wheelchairs, driverless transport
clothing when handling batteries.
systems, electric motor boats.
Observe Accident Prevention Regula-
– Starter batteries tions as well as DIN VDE 0510,
for cars, trucks, motor-cycles, boats, ships. VDE 0105 T.1.

– Batteries for storing regenerative energy No smoking!

for independent power supply systems in Naked flames, glowing materials or
individual houses, back-up power supplies, sparks should be kept away from
hobby and camping, solar power plants. vicinity of battery in order to avoid risk
of explosion or fire.
– Batteries for special purposes
e.g. for clocks and watches, signalling devices, Any splashes of acid that make contact
fire and intrusion detectors, hobby construc- with eyes or skin should be immediately
tion kits, ships at sea or boats on inland rinsed off with plenty of clear water.
waterways. Afterwards consult a doctor without
delay. Any clothing contaminated with
Main specifications for batteries acid should be washed out in water.
– high energy density
Explosion and fire hazard! Avoid
– small dimensions creating a short-circuit. Caution! Metal
– low weight parts of battery cells are always live;
do not place any loose objects or tools
– long service life on top of battery.
– good performance at all temperatures
Electrolyte is highly caustic. Under
– low manufacturing costs normal operating conditions it is not
– ecologically harmless both during production possible to come into contact with
and when subsequently recycled electrolyte. If casing is destroyed,
leaked condensed electrolyte is just
– minimal maintenance requirement. as caustic as liquid electrolyte.

Use only approved lifting and transport

equipment, e.g. lifting gear that con-
forms to VDI 3616. Lifting hooks must
not cause damage to cells, connectors
or connecting cables.

Return to manufacturer!
Waste batteries with this symbol are a
reusable commodity and should be
recycled accordingly. Batteries that
are not intended to be recycled must
be disposed of as hazardous waste in
accordance with all associated regula-
tions.

4
Battery Technology

Battery construction

1 Grid with diagonal structure for better 7 Block of plates

derivation of current
= improved cold-start performance 8 Central gas dissipation channel

2 Negative grid plate (grey surface) 9 Vent plug with O-ring seal,
moisture and acid vapour can not
3 Positive grid plate, jacketed escape upwards
to prevent short-circuits
(reddish surface) 10 Terminal exit, impervious to electrolyte

4 Positive plate group with 11 Cell without V-supports (space used as

jacket separators sediment well)

5 Bus bar, impervious to electrolyte, 12 Intercell connector

gives improved voltage characteristics
due to shorter current paths 13 Folding handle

6 Negative plate group

(grey surface)

5
 Battery Technology

Electrochemical process in a low-maintenance battery

Charged state Charge cycle

The active material of the positive plate consists While charging is taking place – the positive
of lead dioxide (PbO2), and the negative plate is plate is connected to the positive terminal and
made of metallic lead sponge (Pb). Both plates the negative plate with the negative terminal of
are immersed in an electrolyte of diluted a DC voltage source (charger) – the chemical
sulphuric acid (H2SO 4). A voltage can be reaction is repeated but in reverse order.
measured across the terminals, which can be Electrons are drawn off the positive plate and
calculated according to the following formula: transported to the negative plate via the DC
voltage source. The lead sulphate of the positive
U0 Acid density plate is converted back into lead dioxide and
= + 0.84 the lead sulphate of the negative plate becomes
Volts kg/l
lead sponge again. At the same time water is
Example: With an acid density of 1.27 kg/l, the consumed and sulphuric acid formed. The
potential difference is density of the electrolyte increases. The water
U0 = 1.27 + 0.84 = 2.11 volts/cell. that has been consumed must be replaced.

Discharge cycle Charged state

When the terminals of charged plates are All the lead sulphate will have been transformed
connected to a load, electrons flow from the back into PbO2 and Pb when the density of the
negative plate via the external circuit to the electrolyte and the terminal voltage cease to
positive plate. The battery is therefore rise during the charging cycle. The state
accomplishing electrical work. Simultaneously, described in para 1 has been reached. The
a chemical reaction begins on both plates, cycle has been completed and the discharge
whereby sulphuric acid is consumed and water cycle can begin afresh.
formed. The active materials are transformed
into finely distributed lead sulphate (PbSO4).
This process maintains the flow of electrons
within the external circuit. Therefore the density
of the electrolyte is continually reducing while
discharging is taking place.

Discharged state

When the voltage at the terminals has reached

its pre-determined minimum level during the
discharge cycle, the chemical reaction has been
completed and the active materials that make
up the positive and negative plates have been
transformed into lead sulphate. As a result the
density of the electrolyte has reduced con-
siderably.

6
Battery Technology

Electrochemical process in a low-maintenance battery

7
 Battery Technology

Electrochemical process in a maintenance-free battery

Maintenance-free batteries are completely Advantages
sealed against loss of electrolyte. The safety
valves in the top cover merely serve to protect – maintenance-free
the battery from potential overloading (= excess
pressure). The grid plates are made from a – no particular requirements with reference to
special lead alloy that contains no antimony, positioning
and the separators from a fibreglass micromesh.
– can be transported without risk of leaking
In the case of a low-maintenance battery with electrolyte (not classified as dangerous
liquid electrolyte, water is converted into material)
hydrogen and oxygen. These gases escape
out through the vent plugs. The loss must be – safe from overdischarging
compensated by topping up with distilled water.
– minimum space requirement
In the case of maintenance-free batteries, the
electrolyte is bound into a fibreglass micromesh, – long shelf life
the pores of which are 90 % filled. The first step
in the charging process is the development of
oxygen at the positive plate. This oxygen passes
directly through the free pores to the negative
plate. Here it recombines with the H+ ions to
form water again. During this process the
negative electrode is depolarised, so that
practically no hydrogen is developed. The water
diffuses back to the positive plate. The processes
of decomposition and recombination represent
a complete cycle. There is therefore no loss of
water within the cell.

With maintenance-free batteries, the gases can

be recombined into water due to the chemical
processes inside the sealed cell.

The water inside the cell decomposes into

oxygen at the positive plate and hydrogen at
the negative plate.

The oxygen passes through fissures and

channels in the gel and through the microcellular
separators to the negative plate, where it
combines with ions of hydrogen to form water
again. This water is absorbed by the gel. This
means that the battery is entirely maintenance-
free.

For safety reasons, maintenance-free batteries

are always fitted with a valve which opens if the
internal pressure rises to approx. 60–100 mbar.
The valve closes again automatically as soon
as the excess pressure has been released.

8
Battery Technology

Electrochemical process in a maintenance-free battery

1 Positive plate (anode) Discharge cycle:

2 Separator (fibreglass micromesh with ½ O2 + Pb + H2SO4 = PbSO4 + H2O

electrolyte)
Charge cycle:
3 Negative plate (cathode)
PbSO4 + E = Pb + SO4

E = energy (charger)

H = hydrogen

O2 = oxygen

Pb = lead

H2SO4 = sulphuric acid (electrolyte)

PbSO4 = lead sulphate

H 2O = water

9
 Battery Technology

Charging technology and characteristic curves

The chemical processes that occur during the The following criteria must be taken into account
discharging and charging cycle can not be when matching a battery to a charger:
changed; they are derived from the basic laws
– battery (nominal voltage, nominal capacity)
of nature. In practical terms however, different
methods of charging have been developed – battery type (low-maintenance/maintenance-
according to operating requirements. These are free)
defined by DIN 40 729 and can be described – breaks in use, i.e. intervals when battery is
precisely on the basis of their charging curves. out of service
The main features of the charging devices and
methods which work according to these curves – charging duration
are described in the following four paragraphs, – intermediate charges
together with diagrams that illustrate the
progression of the charging current during the – equalising charges
charging period for each of the different curves.
DIN 41 772 defines the types of curve and These factors determine the:
associated symbols that apply to the rectifiers – type of charging device, i.e. the charging
currently in use as follows: curve

I= constant-current curve – nominal voltage of charger

– nominal current of charger
U = constant-voltage curve
Important
W = resistance curve (falling current)
It is essential that the battery manufacturer’s
O = automatic change-over from one curve specifications are used as the basis for identify-
to another ing the correct charger or charging curve for a
particular battery. The wrong combination with
a= automatic switch-off incorrectly matched charging currents can result
in the following:
Chargers must also maintain certain tolerances
with respect to current and voltage: – differing charging time
– with I curves according to DIN 41 773: ± 2 % – battery temperature too high
of the current, ± 1 % of the voltage, – excessive gassing
– with W curves according to DIN 41 774: – decomposition of the active material
± 0.05 volts per cell.
– high water consumption
Both unregulated and regulated devices are – increased corrosion
used for charging. Unregulated chargers with
so-called W curves (Wa, WOWa, etc.) are – insufficient charge
affected by fluctuations in the mains voltage. – overcharging
Regulated devices are able to compensate for
these fluctuations. – short service life

Both the primary and the secondary charging

currents are determined by the battery capacity.
See “General technical specifications”.

10
Battery Technology

Charging technology and characteristic curves for low-maintenance

batteries
Wa curve (e.g. for an 80 Ah battery)

The most widely employed method of charging charging has been completed, the device
corresponds to the Wa curve. The battery is switches off automatically. 9–12 hours are
connected to a charger that matches its voltage required to fully charge a battery.
and capacity. Special circuitry controls the
charging process fully automatically, i.e. when

WU1U2 curve (e.g. for a 40 Ah battery)

This method of charging is employed when place as soon as the prescribed voltage and
there is sufficient time available, as the first current levels have been reached. The primary
charging phase corresponds to a W curve as charge is followed by a compensation (trickle)
opposed to an IU curve. The change-over takes charge.

IUIa curve (e.g. for a 175 Ah battery)

The IUIa curve enables batteries to be charged can also charge maintenance-free batteries.
very quickly. An additional advantage is that by The secondary charging phase ensures that
simply altering the parameters, high-quality the charge state of batteries connected in series
chargers that function according to this method is synchronized.

11
 Battery Technology

Charging technology and characteristic curves for maintenance-free

batteries
IUIa curve (e.g. for a 160 Ah battery)

Devices that functionaccording to this curve are hours. When the IU charge has been completed,
mainly used when there is a limited amount of the battery receives a secondary Ia charge, so
time available for charging. Depending upon that it always reaches its full-charge state. This
how it is configured, this type of charger can method is particularly suitable for charging
fully charge a battery within approximately six batteries connected in series.

IU curve (e.g. for a 40 Ah battery)

The IU curve is particularly suited to the charging The advantages of these charging systems lie
of single-cell batteries, block batteries and in the fact that several batteries can be charged
batteries in commercial-sized installations where in parallel at the same time without the need for
a large number of batteries of the same nominal consideration of their capacity and their state of
voltage but of differing capacity are to be charge.
charged.

12
Battery Technology

Information about battery charging

– In order to maximise the service life of a The acid density should not drop below
battery, it is fundamentally important to avoid 1.13 kg/l. Only purified water (distilled or
totally discharging the battery. demineralized) that conforms to DIN 43 530
Part 4 should be used to top up the cells.
– A total discharge occurs when the current
drawn from the battery exceeds 80 % of its – Pay careful attention to the charger operating
nominal capacity. Frequent repetition will instructions.
cause damage to the battery.
– Various chargers must be RESET before
– Batteries whose power has been drawn down charging commences, i.e. switch charger OFF
by at least 50% must be charged immediately and ON again. If this procedure is overlooked,
after removal. Never leave batteries standing charging will not take place.
for any period of time or store them if they are
in a state of deep-discharge. – Chargers that can be switched to different
voltage outputs should be set to the correct
– Batteries can be affected by sub-zero tem- charging voltage. The battery will be damaged
peratures and should therefore be stored if charged at the wrong voltage.
only in a state of charge.
– If the charging process is terminated because
– If the battery is occasionally totally discharged, insufficient time is available to achieve the
extensive damage can be avoided by giving full-charge state, the battery capacity will
it an equalising charge straight away. slowly reduce every time the charging cycle
is not completed. In this case the battery
– With maintenance-free batteries, the tem- must be subjected to a full charge at least
perature should not exceed +40 °C. once per week.

– The optimum operating temperature for low- – As a matter of principle there should always
maintenance batteries is below +40 °C and be sufficient time (12–16 hours) to fully charge
the maximum permissible electrolyte tem- a battery after each occasion that it has been
perature is +55 °C. In order to avoid perma- in use. The time required for charging depends
nent damage to the batteries, these tem- upon the amount of current that has been
peratures should never be exceeded. drawn, the type of battery and the charger
that is being used.
– The temperature of the electrolyte in batteries
that are subjected to heavy loads can rise – The level of electrolyte in low-maintenance
above +55 °C during charging. In such cases batteries should be checked at least once per
the battery must be allowed to cool down and, month and distilled water added, if required.
if necessary, charging must be interrupted.
– If the battery is not in use over relatively long
– The battery terminals must always be con- periods, the voltage should be checked
nected to the charger according to the correct monthly and the battery recharged as
polarity, i.e. positive terminal on battery to required. Self-discharge is approx. 1 % per
positive connection on charger and negative day in low-maintenance batteries and 0.1 %
battery terminal to negative charger con- per day in maintenance-free batteries.
nection. Batteries must be recharged without fail at
the latest at 2.07 V/cell.
– Only use chargers that correspond to the
battery capacity and the local conditions for – If the battery charge has been heavily drawn
use. They should also switch off automatically down as a result of continual partial discharge,
when the final charge has been completed. every 2 to 3 months a job should be carried
out until the deep-discharge protection device
– If the level of electrolyte in the cells is insufficient comes into action or until the machine loses
after the battery has been discharged, they power substantially. The battery must then
must be topped up with water to the prescribed be charged immediately.
level before they are recharged. Never top up
properly functioning cells with acid. Use only – If the battery charge status is sufficient for
purified water, as it is the water that is consumed two jobs, the battery should not be charged
and not the acid. again until they have both been completed.

13
 Battery Technology

Voltage curve during one complete discharge/charge cycle

for two battery blocks connected in series

The diagram shows the typical behaviour of a a rapid reduction in the operating time of the
set of two battery blocks, whereby the charge appliance to which it is connected.
state at the end of the operating phase (machine
switched off by total-discharge protection) is A similar process takes place when batteries
considerably reduced in one of the blocks. A with different charge states are used. They
good charger with a secondary charging phase must therefore always be charged separately,
can compensate for minor differences. prior to use.

Greater differences, which are caused when the If the total-discharge protection is set too low,
total-discharge protection is set up incorrectly, the difference between the individual blocks will
can no longer be compensated for in the long increase with every charge, which will lead to
term. The applicable block will never become the battery becoming unserviceable within a
fully charged, which means that it suffers a short period of time.
permanent loss of capacity. This in turn leads to

14
Battery Technology

State of charge of a low-maintenance battery

Off-load voltage State of battery charge subject to acid
density and temperature
A measurement which will give a good indication
for a low-maintenance battery can only be carried Acid density
out when the battery is in a state of charge.
Check the liquid level in the battery beforehand
1 fully charged
and if required fill up with distilled water. When 2 partially discharged
the battery has been filled up with water, it is 3 discharged
absolutely necessary that it is charged again
before the off-load voltage is measured.

Acid density

Temperature

The off-load voltage should reach the following

threshold values at least:
2-volt cell ............. threshold value 2.03 volts
6-volt block .................................... 6.10 volts
12-volt block ................................ 12.20 volts
The acid siphon is used in low-maintenance If there proves to be a difference in the threshold
batteries for removing the appropriate amount value of more than 1 volt/block or 0.2 volts/cell,
from the battery and for measuring the then the block or the cell with the lowest voltage
concentration. A reading can be taken on the should be replaced.
acid siphon to see if the concentration is all
right. It may be necessary to recharge the
battery. The difference between the individual
cells may be 0.04 kg/l at maximum. If the Note:
difference is greater than this, there is either a Some older batteries may show signs of
short circuit, a handling error (exhaustive acid layering, that is to say a weak acid
discharge) or wrong usage. In this case the overlays one which is highly concentrated.
block in question or the cell must be replaced. As a result it is easy to arrive at a wrong
reading. Before measuring the acid density,
Acid density (kg/l) Charge approx. therefore, it is advisable to tilt the battery
at +20 °C this way and that, making sure however
that no acid comes out.
1.24–1.28 75–100 %
1.20 50 %
1.12 25 %
≤ 1.12 deep discharge state

15
 Battery Technology

State of charge of a maintenance-

free battery
Off-load voltage

The off-load voltage in a maintenance-free The off-load voltage should reach at least the
battery is a measure of its state of charge. If it following threshold values:
lies below a certain threshold value it is a sign
2-volt cell ............. threshold value 2.05 volts
that the battery is not charged.
6-volt block .................................... 6.15 volts
The available charge can be gauged
12-volt block ................................ 12.30 volts
approximately from the off-load voltage:
If these values have not been reached, the
12-volt block 6-volt block Charge battery must be charged.
approx.
≥ 12.80 volts ≥ 6.42 volts 100 %
≥ 12.55 volts ≥ 6.30 volts 75 %
≥ 12.32 volts ≥ 6.20 volts 50 %
≥ 12.18 volts ≥ 6.10 volts 25 %
≤ 12.00 volts ≤ 6.00 volts deep
discharge
state

16
Battery Technology

Operating modes
Functional reliability depends to a great deal There must be sufficient time available to fully
upon selecting the correct mode of operation. charge the battery after the operational capacity
The operating modes are therefore described has been consumed. A suitable charging device
in detail here and illustrated with diagrams. The that corresponds to the characteristics of the
first diagram shows the discharge and charging battery must be used for recharging.
cycle on the basis of a 24-hour day, irrespective
of the type of battery or any physical-chemical Control devices that have been matched to the
considerations. The appropriate battery curves type of battery and approved by the battery
are explained in conjunction with the operating manufacturer should be employed for monitoring
modes, as are any special features. the charge state of the battery. Battery charge
indicators that have been set up for a discharge
The following operating modes are employed in voltage appropriate to low-maintenance batteries
conjunction with cleaning machines: with an acid density of 1.27 kg/l should be
adjusted for a higher end voltage when used
– discharge cycle with no intermediate charge
with maintenance-free batteries. This is because
– discharge cycle with an intermediate charge the acid density in maintenance-free batteries is
higher. If this adjustment is not made, the result
will be a totally discharged battery. Charge state
Discharge cycle with no intermediate indicators that function by measuring the no-
charge load voltage – as is common practice with low-
maintenance batteries – are not suitable for use
When describing the discharge process, it is with maintenance-free batteries. As a result of
assumed that the battery was fully charged at the loss of water that occurs while the battery is
the start of the working shift. The battery capacity in use, the acid density increases and with it the
is calculated so that the operational capacity, discharge voltage. This leads to errors in
i.e. 80 % of the nominal capacity, is available indication and totally discharged batteries. It is
for the full duration of the working shift. The therefore a good idea to always make use of a
maximum limits (current, temperature, etc.) must special charge state indicator that corresponds
not be exceeded while the battery is discharging. to the type of battery that has been selected.

17
 Battery Technology

Discharge cycle with an intermediate charge

With the discharge process that takes in an After the operational capacity has been
intermediate charge, it is also assumed that the consumed, i.e. 80 % of the nominal capacity,
battery was fully charged at the start of the there must be sufficient time available to fully
working shift. The battery capacity is calculated charge the battery. With intermediate charging
so that the operational capacity, i.e. max. 70 to it is possible to achieve a daily consumption of
80 % of the nominal capacity plus the sum of operational capacity of max. 1 x C5. In order to
the recharge cycles, is sufficient to last for the ensure that the intermediate charge has the
full duration of the working shift. The higher desired effect upon the capacity, it should not
throughput of energy gives rise to higher battery be carried out until the battery has reached
temperatures which shorten the length of time approx. 50 % of its nominal capacity. The
that the battery can be used. The maximum duration of the intermediate charge should not
limits (current, temperatures: for low- exceed 1.5 h.
maintenance +45 °C, for maintenance-free
+40 °C, etc.) must not be exceeded while the
battery is in use.

18
Battery Technology

Operational capacity
The operational capacity is a significant factor sheets refer exclusively to a 5-hour period during
when planning energy requirements. As the which current (I5) is drawn. On its own, this is not
data sheets issued by battery manufacturers enough for defining energy requirements.
refer exclusively to the nominal capacity of a Different levels of current are drawn from
battery, it is necessary to consider the actual batteries during normal operation. An installation
operational capacity that is available. In order must configured in such a way as to ensure that
to avoid any consequential damage, but more the maximum limits are never exceeded. If the
especially to achieve the useful life specified by discharge current is too high, the battery could
the battery manufacturers (number of charging be drained until the charge state (LZ =
cycles), only 60 to 80 % of the nominal capacity, Ladezustand) is 0 %. In the case of lower
i.e. the operational capacity per working cycle, discharge currents, the battery should only be
should be consumed, whatever the type of work discharged to a charge state of 20 %, for
being undertaken.Maximising the useful life of example.
a battery depends to a large degree upon
whether the maximum limits specified in the The usable operational capacity is also
data sheets are adhered to. The operating dependent upon the length of time that current
temperature, in particular, is one criterion that is drawn. For example, drawing large currents
has a significant effect upon the maximum for short periods of time results in reduced
useful life of a battery. efficiency and a considerable increase in the
battery temperature. This in turn reduces the
The operational capacity mainly depends upon number of times that a battery can be charged
the operating temperature, the discharge current and therefore its service life, because the rate
and the length of time that current is drawn. The at which the chemical reactions take place
capacity figures (C5) quoted in battery data inside the battery is increased.

Relationship between number of possible charging cycles (%) and operating temperature.

19
 Battery Technology

Nominal capacity
The nominal capacity is the amount of electricity A low-maintenance battery that is subjected to
that can be drawn from a battery under nominal repeated charging cycles should not be
operating conditions (discharge current, discharged beyond 20 % of the nominal capacity
discharge time, discharge end-point voltage, Cnom. In addition to this, an ageing factor of 0.9
temperature, density and level of electrolyte). should be taken into consideration. If, for
The nominal capacity Cnom is laid down by the example, the requirement is for 500 Ah5, then
manufacturer. the battery must have a nominal capacity of at
least:
Note:
Example
The following specifications are normally used
in DIN standards and IEC publications relating 500 Ah5
Cnom = = 694 Ah5
to traction batteries:
(100 % –20 %) x 0.9
C5 = capacity for a 5-hour discharge period,
e.g. 160 Ah5
694 Ah5
TN = nominal temperature +30 °C I5 = = 138.8 A
(reference temperature) 5h
US = end voltage after discharge
at least 1.7 volts/cell
I5 = discharge current over 5-hour At the end of a 5-hour discharge period, the end
discharge period voltage (Us) must still be at least 1.7 volts/cell.
C5
5h

20
Battery Technology

Service life
The economical and efficient use of an appliance Under laboratory conditions the temperature
depends to a large degree upon the traction fluctuations are limited, which is reflected by the
battery and its durability. Use of specially relatively constant temperatures measured in
selected materials and faultless production the individual cells during testing. In practice, all
quality favourably influence the durability or sorts of influences acting on the battery cause
service life. German standard DIN 43 539 Part the temperature to fluctuate, which can differ
3 has been drawn up to create a neutral method considerably from the ideal “30 °C conditions”.
of evaluating this important feature of traction Increased temperatures – especially those above
batteries. This standard sets out quite clearly +40 °C – have a particularly negative effect upon
how, and with what measuring equipment, tests the service life, because all the chemical
are to be carried out under laboratory conditions. reactions, including the detrimental secondary
This has created an objective framework for reactions, are carried out at a faster rate.
many different purposes, such as
When considering the factors that influence the
– comparing different products
service life of a battery, special attention must
– testing manufacturing quality be given to the charging technology. The
following general principles must be taken into
– basis for carrying out further development.
account whenever maintenance-free traction
In the case of laboratory measurements carried batteries are to be used, in order that the battery
out according to this procedure, the durability can give the longest possible service life.
for traction batteries with armour/tubular plates, 1. Charging should only be carried out using
i.e. cells that conform to DIN 43 595, should devices that have been recommended by the
equate to 1500 cycles. The cyclic test, which battery manufacturer and which function
precisely defines the frequency of charging and according to the optimum charging curve for
discharging, is considered to have been the battery.
completed when the available capacity has
2. The optimum service life is achieved by not
reduced to below 80 % of the nominal capacity.
discharging the battery beyond 60 % of its
However, this durability does not simply convert nominal capacity. Discharging the battery
into the service life that can be expected under beyond 80 % should be avoided under all
normal conditions of use. Real parameters must circumstances.
be applied in practice, and these can reduce 3. The maximum operating temperature of
the number of charge/discharge cycles in varying +40 °C should not be exceeded.
degrees.
4. It is only permissible to use the battery for a
Unlike a cell when it is tested in the laboratory, single working shift at a time, in order that the
batteries are subjected to severe mechanical battery has sufficient time to cool down.
stresses during normal use that reduce the
Non-observance of these rules could lead to
service life of certain parts. For example, this
premature failure of the battery. The following
applies to terminal exits, welds or the adhesion
diagrams enable the expected useful life to be
of the active material to the grid plates.
calculated on the basis of the associated
According to DIN 43 539 Part 3 discharge takes operating conditions.
place during the durability test at constant current
= 1.25 x I5. In practice, however, we find there
is a very broad load spectrum: sometimes higher
currents and therefore greater heat loss, or
substantially lower currents which lead to
extreme demands on the active material
because of higher utilisation.

21
 Battery Technology

Service life
The following two examples illustrate how the diagrams are to be used in the case of low-
maintenance armour-plate batteries:
Example 1 Example 2

Operating parameters:
average discharge current 1 x I5 (A) 1 x I5 (A)
average operating temperature +30 °C +45 °C
number of times discharged per day 1 1.5
number of days in service per year 240 220
the expected service life in months
that can be read off the diagram: 60 28

22
Battery Technology

Care and maintenance

It is absolutely necessary to keep the battery It can therefore be seen that cleaning the
clean. This is not just a matter of appearance, batteries is not only necessary to ensure that
but it is also to avoid accidents and damage, or they are always readily available for use, but
a reduced service life and availability of the also a significant requirement for complying
battery for use. with Accident Prevention Regulations.
It is necessary to clean the cell arrays, trays,
Battery blocks are supplied filled with electrolyte
mountings and insulators in order to ensure that
and charged. The service life of the batteries
the cells are properly insulated from one another,
starts as soon as they are used for the first time.
from earth or from any other conductive object.
The cells in the battery are subject to self-
In addition, cleaning helps to avoid damage
discharging. The amount of self-discharging
caused by corrosion and leakage currents.
depends upon temperature and the storage
The insulation resistance of traction batteries time. Different charge states therefore occur in
that conform to DIN VDE 0510 Part 3 must be the battery cells as a result of different storage
at least 50 W per volt based on the nominal times and/or different temperatures. Batteries
voltage. In the case of batteries for electrically should therefore be stored in a uniformly cool
powered industrial trucks that correspond to and dry environment.
DIN VDE 0510 0117, the insulation resistance
must not be less than 1000 W.
A battery is an item of electrical equipment that
has exposed connections which are protected
from accidental contact by insulating covers.
This cannot however be treated as the
equivalent of a full electrical insulation because
there is a voltage present between the terminals
and the connecting posts which pass through a
non-conducting plastic lid.
It is not possible to prevent dust from accumu-
lating on the battery. The amount will vary
according to location and duration of use. Small Relationship between self-discharging process
amounts of electrolyte particles that escape and temperature, in the case of maintenance-
when the charging voltage rises above the level free batteries.
at which gassing begins form a layer on the The rate at which self-discharging takes place
cells or the block covers that is more or less is doubled for every +10 °C increase in
slightly conductiver. So-called leakage currents temperature.
flow through this layer. The result is increased
When series-connected battery blocks with
and varied levels of spontaneous discharging
different charge states are taken into use, the
in the cells or block batteries.
cells with the lower charge state will be subject
This is one of the reasons why drivers of to total-discharging and insufficient charging
electrically powered vehicles complain about with sulphating, and the cells with the higher
insufficient capacity when a battery has been charge state will be subject to overcharging
idle for a longer period of time, such as over the with an increased water consumption (or severe
weekend. sulphating).The charging method is matched to
If the leakage currents are quite large, there is the technology of the sealed battery and is not
a possibility that sparks may occur which could able to completely compensate for the different
cause the gases formed during charging charge states in individual cells. Before
(electrolytic gas) to explode, as they escape combining battery blocks together to form one
through the cell plugs. traction battery, it is important to make sure that
all the battery blocks are fully charged or at least
have the same charge state.

23
 Battery Technology

Care and maintenance

– The battery should be removed from the High-pressure cleaners can be used on vehicle
vehicle for cleaning. traction batteries with cells that correspond to
DIN 43 595, DIN 43 599 and DIN 43 579 Part 4.
– At the location where cleaning is to take
place, it must be possible to direct the water The following points must be observed when
used for rinsing the battery, and which will cleaning the battery so that no damage is
have been contaminated with electrolyte, caused to plastic parts, such as the cell covers
into a suitable waste-water treatment plant. or the insulation for the intercell connectors and
Industrial Safety and Accident Prevention the vent plugs:
Regulations, as well as regulations that apply
– Intercell connectors must be connected tightly
to water and waste disposal, must be
or plugged-in firmly.
observed when disposing of used electrolyte
or contaminated water. – Vent plugs must be inserted and closed.
– Safety goggles and protective clothing are to – No detergents are to be used.
be worn. – The maximum permissible temperature at
– Vent plugs should not be removed or opened, which the cleaner may be operated is +140 °C.
but should keep the cells closed off. Any As a rule, this will ensure that the temperature
instructions on cleaning supplied by the at a distance of 30 cm from the nozzle does
manufacturer must be observed. not exceed +60 °C.
– Plastic parts of the battery, especially the cell – The distance from the tip of the high-pressure
jars, should only be washed with water or nozzle to the surface of the battery should not
cleaning rag soaked in water without any be less than 30 cm.
additives. – The maximum operating pressure is 50 bar.
– When cleaning has been completed, the – The jet should be continuously moved across
battery must be dried using appropriate the whole surface of the battery so that there
means, e.g. compressed air or cleaning rag. is no overheating at any one spot.
– Any liquid that collects in the battery tray must – Do not direct the jet at any one location on the
be siphoned off and disposed of in accordance battery for longer than 3 sec.
with the regulations mentioned above.
– When cleaning has been completed, the
battery must be dried using appropriate
means, e.g. compressed air or cleaning rag.
– Hot-air blowers with a naked flame or heating
wires must not be used.
– The temperature on the surface of the battery
should not exceed +60 °C.

24
 Battery diagnostics (low-maintenance)

Battery Technology
1. Visual inspection

Diagnosis Possible causes Potential consequences Remedy

Damaged casing, cracks, dents Transport damage, incorrect Electrolyte could leak out Replace battery
handling

Battery terminals are blue/black Clamp not properly tightened Battery terminal could melt, Tighten clamp, or replace
battery becomes too hot, battery if badly damaged
reduced service life

Electrolyte leaking from vent plugs Battery has been overcharged Reduced service life Check level of electrolyte and acid
(wrong charger) density, and top up if required.
Check charger, recharge or replace
battery.

Battery has been tipped to one Surrounding materials become Check level of electrolyte and acid
side corroded density, and top up if required.
Check charger, recharge or replace
battery.

Very dirty battery exterior Working environment, cover is Leakage currents, spontaneous Clean battery, attach cover
missing discharging, electrolyte is
contaminated when plugs are
opened, battery could be destroyed

Electrolyte is cloudy Large number of completed cycles Short-circuit inside battery (between Check charger, replace battery
(age), wrong charger, large cell plates), battery could be
amount of suspended matter in destroyed, increased explosion
electrolyte hazard
25
26

Battery diagnostics (low-maintenance)

2. Acid density and no-load voltage

Diagnosis Possible causes Potential consequences Remedy

Measure acid density in all cells If values for individual cells are too reduced battery capacity Adjust electrolyte for correct acid
when battery is fully charged: low: density and level inside cell, charge
specified value at +30 °C or replace battery
– electrolyte has leaked and has
= 1.27 ± 0.02 kg/l
been replaced with
– spontaneous discharging
– contaminated electrolyte
– electrolyte has not been
thoroughly mixed
Note:

Shake battery gently to ensure If values for individual cells are too reduced battery capacity and Adjust electrolyte for correct acid
that electrolyte is thoroughly high: service life density and level inside cell, charge
mixed before measuring acid or replace battery
– electrolyte has been added
density with an acid siphon.
instead of water
– electrolyte has not been
thoroughly mixed
Most acid testers are fitted with
a thermometer. This enables the
acid density to be calculated for
the reference temperature of
+30 °C.
Measure no-load voltage across

Battery Technology
all cells when battery is fully
charged: specified value at
+30 °C = acid density + 0.84
e.g.
acid density 1.27 kg/l
no-load voltage
= 1.27 + 84 = 2.11 volts/cell
 Battery diagnostics (low-maintenance)

Battery Technology
3. Voltage after completion of charging

Diagnosis Possible causes Potential consequences Remedy

The voltage after charging has Defective cells, defective charger reduced battery capacity, Replace battery and/or charger
been completed should be at intensive gassing, explosion
least 2.6 ± 0.5 volts/cell hazard, considerable loss of water
(applies to Wa curve) w

Significantly higher voltage reduced battery capacity, battery Check operating conditions
across individual cells ffails after a short time (overdischarged), check charger to
ensure that battery is receiving a
full charge, charging current too
Significantly lower voltage – varying degrees of wear on cells
high, wrong charger, increase
across individual cells (age)
charging time
– short-circuit inside cell
– charging time was too short
– electrolyte has been over-diluted
27
28

Battery diagnostics (low-maintenance)

4. Capacity

Diagnosis Possible causes Potential consequences Remedy

In order to check the capacity, A discharge end voltage of more than none not applicable
the battery must be discharged 1.7 volts/cell after 5 hours indicates
with a current equal to I 5 that the battery is in good working
until the discharge end voltage order.
US = 1.7 volts/cell has been
reached. Measure the amount of
time (t E ) required for this to
happen (Test Record).
Example: If the discharge end voltage across
Cnom = 160 Ah5 individual cells is significantly lower:
I5 = 160 = 32 A
– battery was not fully charged reduced capacity, battery fails Check charger and charging
tE = 4.5 h – loss of capacity after
a a short time method, check conditions under
C5 = I5 x tE – varying degrees of wear on cells which battery is used, replace
(age) battery
= 32 x 4.5 = 144 Ah – short-circuit inside cell
– battery was used with incorrect
= 90 % Cnom acid density
= battery is in good – over-discharged
working order – wrong charger
If the discharge end voltage of – battery unsuitable for application
1.7 volts/cell is reached after only
3 hours:

Battery Technology
C5 = 32 x 3 = 96 Ah
= 60 % Cnom
 Battery diagnostics (maintenance-free)

Battery Technology
1. Visual inspection

Diagnosis Possible causes Potential consequences Remedy

Damaged casing, cracks, dents Transport damage, incorrect Electrolyte could leak out, battery Replace battery
handling could dry up

Battery terminals are blue/black Clamp not properly tightened Battery could become too hot, Tighten clamp, or replace
reduced service life battery if badly damaged

Casing has swollen Battery has been overcharged Reduced service life Check charger, replace battery.
(wrong charger)

Very dirty battery exterior Working environment, cover is Leakage currents, high level of Clean battery, attach cover
missing spontaneous discharging
29
30

Battery diagnostics (maintenance-free)

2. No-load voltage and charger

Diagnosis Possible causes Potential consequences Remedy

Measure no-load voltage when

battery is fully charged:
specified value:
12.75–0.05 volts for a 12-volt
battery with 6 cells
(2.125 volts/cell)

Measured value < 12.3 volts Battery out of service for too long Sulphating accompanied by loss Apply an equalising charge
(2.05 volts/cell) or defective battery of capacity and premature failure, (see page 43, 8.3),
reduced battery capacity replace battery
Note:
The battery must have been
disconnected from all equipment for
approx. 20 hours before
the no-load voltage is measured.
The no-load voltage is not a reliable
parameter for judging
the condition of a battery.
It is extremely important that Battery will not be fully charged if Battery capacity will be slowly Only use recommended chargers
the recommended charger with recommended charger is not used d reduced with each charging cycle,
indicators for monitoring battery has short service life
the charge state is used.
The operating instructions for

Battery Technology
the charger must be observed.
 Battery diagnostics (maintenance-free)

Battery Technology
3. Capacity

Diagnosis Possible causes Potential consequences Remedy

In order to check the capacity, A discharge end voltage of more than n none not applicable
the battery must be discharged 1.7 volts/cell after 5 hours indicates
with a current equal to I 5 that the battery is in good working
until the discharge end voltage order.
US = 1.7 volts/cell has been
reached. Measure the amount of
time (tE ) required for this to
happen (Test Record).
Example: If the discharge end voltage across
Cnom = 160 Ah5 individual cells is significantly lower:
I5 = 160 = 32 A – battery was not fully charged reduced capacity, battery fails Check charger and charging
5
– loss of capacity after a short time
a method,
tE = 4.5 h – varying degrees of wear on cells check conditions under which
(age) battery is used,
C5 = I5 x tE
– short-circuit inside cell replace battery
= 32 x 4.5 = 144 Ah – over-discharged
= 90 % Cnom – wrong charger
– battery unsuitable for application
= battery is in good
= working order
If the discharge end voltage of 1.7
volts/cell is reached after only 3 hours:
C5 = 32 x 3 = 96 Ah
= 60 % Cnom
31
 Battery Technology

Batteries and battery chargers for sweepers

KMR 1050 S BAT P

KSM 690 Profi P 2)
Low-maintenance

KSM 950 S BAT P

Maintenance-free

KMR 1050 S BAT

KMR 1250 BAT P

KSM 690 Profi 1)

KSM 750 Profi P

KSM 690 BAT 1)

KSM 690 BAT 2)

KSM 750 BAT P

KSM 950 S BAT

KMR 1050 BAT

KMR 1200 BAT

KMR 1250 BAT

KSM 750 BAT

KSM 950 BAT

Item Order no. Type

Batteries

1 7.654-002 12 V, 44 Ah X l

2 6.654-058 12 V, 40 Ah X l

3 6.554-017 12 V, 50 Ah X ¦ l

4 6.654-099 12 V, 40 Ah X ¦

5 6.654-018 12 V, 60 Ah X ¦ ¦3)

6 6.654-021 12 V, 60 Ah X ¦ l l 3) ¦3)

7 6.654-048 12 V, 80 Ah X ¦3) l 3) ¦4)

8 6.654-093 12 V, 75 Ah X ¦3)

9 6.654-086 6 V, 175 Ah X ¦5)

10 6.654-088 6 V, 160 Ah X ¦5) l 5)

Battery charger

11 6.654-046 for item 1 ¦

12 6.654-057 for item 2 l

13 6.654-100 for item 3 ¦

14 6.654-101 for item 4 ¦ l

15 6.654-077 for item 5 ¦

16 6.654-076 for item 6 ¦ l

17 6.654-067 for item 5+7 ¦ ¦ l

18 6.654-068 for item 6 l ¦

19 6.654-102 for item 8 ¦

20 6.654-054 for item 7 ¦

21 6.654-110 for item 9 ¦ l

22 6.654-084 for item 10 ¦

Batteries + Battery charger

23 2.815-231 4x 6 V, 160 Ah X ¦

24 2.815-232 24 V, 240 Ah X ¦

25 2.815-256 24 V, 240 Ah X ¦ l

1)
for units up to factory no. 19581
2)
for units from factory no. 19582
3)
unit requires 2 pieces
4)
unit requires 3 pieces
5)
unit requires 4 pieces

l included in the supplied kit

¦ possible accessory

32
Battery Technology

Batteries and battery chargers for floor scrubbers

Low-maintenance

Maintenance-free

BR/BD 1000 BAT

BR/BD 530 BAT

BR/BD 550 BAT

BR/BD 700 BAT

BD 450 BAT

BR 900 BAT
Item Order no. Type

Batteries

1 6.654-018 12 V, 60 Ah X ¦1)

2 6.654-021 12 V, 60 Ah X ¦1)

3 6.654-049 36 V, 175 Ah X ¦

4 6.654-050 36 V, 160 Ah X ¦

5 6.654-043 36 V, 560 Ah X ¦

6 6.654-097 12 V, 80 Ah X ¦1)

7 6.654-093 12 V, 75 Ah X ¦1)

8 6.654-070 24 V, 175 Ah X ¦

9 6.654-071 24 V, 160 Ah X ¦

10 6.654-052 24 V, 350 Ah X ¦

Battery charger

11 6.654-067 for item 1+6 ¦ ¦

12 6.654-068 for item 2 ¦

13 6.654-102 for item 7 ¦

14 6.654-072 for item 8 ¦

15 6.654-078 for item 9 ¦

16 6.654-053 for item 10 ¦

17 6.654-079 for item 3 ¦

18 6.654-051 for item 4 ¦

19 6.654-044 for item 5 ¦

1)
unit requires 2 pieces

l included in the supplied kit

¦ possible accessory

33
Diagnostic Report Battery Technology

DIAGNOSTIC REPORT FOR COMPLAINTS ABOUT BATTERIES

Customer: Service Engineer:
Name ______________________ Name _____________________
Address ______________________ Dealer _____________________
______________________ Date _____________________
Customer no. ______________________ Signature _____________________

1. Equipment
Type ___________________________________________________________
Number ______________________ Works no. _____________________
Visible condition? ___________________________________________________
How long in use? ___________________________________________________

2. Reason for complaint

o available operating time has reduced significantly o no power from battery
o equipment last used on ________________________________________________

3. Equipment usage
o daily, how many hours? ________________________________________________
o weekly, how many hours? ______________________________________________
Type of floor surface o smooth o medium o rough

4. Type of battery used

Type Kärcher Part No. _________________________
o 12 volts o 24 volts o 36 volts
o maintenance-free o low-maintenance
o Liquid level sufficient o Liquid level too low
are the pole shoes tightened properly? YES o NO o
what damage is identifiable? _______________________________________________

5. Type of battery charger used

Type Kärcher Part No. _________________________
o 12 volts o 24 volts o 36 volts
How long in use?________________________________________________________
Are the charging, battery and equipment plugs OK? YES o NO o
Is there any visible damage? ______________________________________________

34
Battery Technology Diagnostic Report

6. Battery charging
o daily o after every use o weekly
o charger remains connected over the weekend
When was the battery last charged?

Situation with the customer YES NO Action if NO

Is the unit suitable for the purpose o o Advise customer

for which it is intended?
If NO, why not?

Are the correct batteries being used? o o Advise customer

Do all blocks look as though o o Replace damaged block

they are all right?

Is the correct battery charger o o Advise customer

being used?

Is the functioning of the battery o o Change battery charger

charger indicated?

Performance values of the battery charger

when battery connected
after 1 minute:
charging voltage volts
charging current amps

Is the protection against deep o o Install deep-discharge

discharge properly installed? protection
volts before the installation

Has the customer made changes o o

to the machine?
If YES, which?

35
Diagnostic Report Battery Technology

7. Measurement protocol
7.1 Maintenance-free battery 2nd Measurement: voltage after the
1st loading test
1st Measurement: Off-load voltage
Run the unit for 5 minutes (not in driving mode).
The off-load voltage in a maintenance-free Afterwards, while the unit is running measure
battery is a measure of its state of charge. If it the voltage. As an alternative, the loading test
lies below a certain threshold value it is a sign can also be carried out with only the suction
that the battery is not charged. turbine or main brush switched on.
The off-load voltage should reach at least the For the 1st and 2nd measurement, the difference
following threshold values: between the 6-volt blocks should not exceed
0.07 volts and the difference between the 12-volt
Cell / block Threshold value (volts) blocks should not exceed 0.15 volts. If the
blocks are older than 6 months an admissible
2-volt cell 2.05
voltage difference would be 0.1 volts for 6-volt
6-volt block 6.15 blocks and 0.2 volts for 12-volt blocks.
The block with the lowest voltage should be
12-volt block 12.3 replaced.
If this procedure still fails to give a clear indication
If these values have not been reached, the of a defective cell or block, the 3rd measurement
battery must be charged before further will have to be carried after the second loading
measurements are carried out. If the off-load test.
voltage lies above these values the 2nd
measurement can be proceeded with imme-
diately. 3rd Measurement: voltage after the
2nd loading test
The available charge can be gauged approxi-
mately from the off-load voltage: Continue to run the unit until the protection
against deep discharge comes into action.
12-volt block 6-volt block Charge Thereafter measure the voltage again when the
approx. turbine/main brush is switched on. One or
several blocks/cells will then usually differ clearly
≥ 12.80 volts ≥ 6.42 volts 100 %
from one another so that the fault can be
≥ 12.55 volts ≥ 6.30 volts 75 % reliably identified.

≥ 12.32 volts ≥ 6.20 volts 50 % Replace the block/cell with the lowest voltage.

≥ 12.18 volts ≥ 6.10 volts 25 %

≤ 12.00 volts ≤ 6.00 volts deep
discharge
state

36
Battery Technology Diagnostic Report

Measurement protocol for maintenance-free block batteries

(Please tick unit concerned)
1st measure- 2nd measure- 3rd measure-
ment ment ment
Voltage Voltage Voltage

o KSM 690 volts volts volts

o KSM 750
1 x 12 volts

o KSM 750 Profi 1 1 volts volts volts

o KSM 950
o BR/BD 450
2 2 volts volts volts
o BR/BD 530
2 x 12 volts

o KMR 1200 1 2 1 volts volts volts

o KMR 1250 2 volts volts volts
o BR/BD 530 3 volts volts volts
3 4
o BR/BD TRIKE 4 volts volts volts

4 x 6 volts

o BR/BD 700 1 2 1 volts volts volts

2 volts volts volts
3 volts volts volts
3 4 4 volts volts volts
5 volts volts volts
5 6 6 volts volts volts

6 x 6 volts

37
Diagnostic Report Battery Technology

7.2 Low-maintenance battery

1st Measurement: Off-load voltage 3rd Measurement: Voltage after the
1st loading test
A measurement which is capable of giving a
good indication for a low-maintenance battery This measurement must only be carried out if
can only be carried out when the battery is in a no clear indication has emerged as to the
state of charge. Check the liquid level in the defective block/cell from the 1st and 2nd
battery beforehand and if required fill up with measurement.
distilled water. When the battery has been filled
Continue to run the unit until the protection
up with water, it is absolutely necessary that it
against deep discharge comes into action. Then
is charged again before a measurement is
measure the voltage again when the turbine/
taken of the off-load voltage.
main brush is switched on. One or several
The off-load voltage should reach the following blocks/cells will then usually differ clearly from
thresholds values at least: one another so that the fault can be reliably
identified.
Cell / Block Threshold value (volts)
Replace the block/cell with the lowest voltage.
2-volt cell 2.03

6-volt block 6.10

12-volt block 12.20

If there is a difference of more than 1 volt / block

or 0.2 volts / cell when the voltage measurement
is taken, the block/cell with the lowest voltage
must be replaced.

2nd Measurement: acid density

The acid density also has to be measured. The
difference between the blocks/cells should not
be greater than 0.04 kg/l. If a block/cell lies
outside this margin, it must be replaced.

Acid density (kg/l) Charge approx.

at +20 °C
1.24–1.28 75–100 %
≥ 1.20 50 %
> 1.12 25 %
≤ 1.12 deep discharge state

38
Battery Technology Diagnostic Report

Measurement protocol for low-maintenance block batteries

(Please tick unit concerned)
1st measure- 2nd measure- 3rd measure-
ment ment ment
Off-load voltage Acid density Voltage

o KSM 690 1 volts kg/l volts

o KSM 750 2 volts kg/l volts
1 2 3 4 5 6 3 volts kg/l volts
4 volts kg/l volts
1 x 12 volts 5 volts kg/l volts
6 volts kg/l volts

o KSM 750 Profi 1/1 volts kg/l volts

o KSM 950 1 1/2 volts kg/l volts
o BR/BD 450 1 2 3 4 5 6 1/3 volts kg/l volts
o BR/BD 530
2 1/4 volts kg/l volts
1/5 volts kg/l volts
1 2 3 4 5 6 1/6 volts kg/l volts
2/1 volts kg/l volts
2 x 12 volts 2/2 volts kg/l volts
2/3 volts kg/l volts
2/4 volts kg/l volts
2/5 volts kg/l volts
2/6 volts kg/l volts

o KMR 1200 1 2 1/1 volts kg/l volts

o KMR 1250 1 2 3 1 2 3 1/2 volts kg/l volts
o BR/BD 530 1/3 volts kg/l volts
o BR/BD TRIKE 3 4
1 2 3 1 2 3 2/1 volts kg/l volts
2/2 volts kg/l volts
4 x 6 volts 2/3 volts kg/l volts

3/1 volts kg/l volts

3/2 volts kg/l volts
3/3 volts kg/l volts

4/1 volts kg/l volts

4/2 volts kg/l volts
4/3 volts kg/l volts

39
Diagnostic Report Battery Technology

Measurement protocol for low-maintenance block batteries

(Please tick unit concerned)
1st measure- 2nd measure- 3rd measure-
ment ment ment
Off-load voltage Acid density Voltage

o BR/BD 700 1 2 1/1 volts kg/l volts

1/2 volts kg/l volts
1 2 3 1 2 3
1/3 volts kg/l volts

3 4 2/1 volts kg/l volts

1 2 3 1 2 3 2/2 volts kg/l volts
2/3 volts kg/l volts
5 6
3/1 volts kg/l volts
1 2 3 1 2 3
3/2 volts kg/l volts
3/3 volts kg/l volts
6 x 6 volts
4/1 volts kg/l volts
4/2 volts kg/l volts
4/3 volts kg/l volts

5/1 volts kg/l volts

5/2 volts kg/l volts
5/3 volts kg/l volts

6/1 volts kg/l volts

6/2 volts kg/l volts
6/3 volts kg/l volts

40
Battery Technology Diagnostic Report

Measurement protocol for low-maintenance batteries in containers

1st measure- 2nd measure- 3rd measure-
(Please tick unit concerned) ment ment ment
Off-load voltage Acid density Voltage
o BR/BD 900 1 volts kg/l volts
1 2 3 2 volts kg/l volts
4 5 6 3 volts kg/l volts
7 8 9 4 volts kg/l volts
5 volts kg/l volts
10 11 12 6 volts kg/l volts
24 volts 7 volts kg/l volts
8 volts kg/l volts
9 volts kg/l volts
10 volts kg/l volts
11 volts kg/l volts
12 volts kg/l volts

o KMR 1200 1 volts kg/l volts

1 2 3 4 5 2 volts kg/l volts
3 volts kg/l volts
4 volts kg/l volts
6 7 8 9 10 5 volts kg/l volts
11 12 6 volts kg/l volts
7 volts kg/l volts
24 volts 8 volts kg/l volts
9 volts kg/l volts
10 volts kg/l volts
11 volts kg/l volts
12 volts kg/l volts

o BR/BD 1000 1 volts kg/l volts

2 volts kg/l volts
1 2 3 4 5 6 3 volts kg/l volts
4 volts kg/l volts
7 8 9 10 11 12 5 volts kg/l volts
6 volts kg/l volts
13 14 15 16 17 18 7 volts kg/l volts
36 volts 8 volts kg/l volts
9 volts kg/l volts
10 volts kg/l volts
11 volts kg/l volts
12 volts kg/l volts
13 volts kg/l volts
14 volts kg/l volts
15 volts kg/l volts
16 volts kg/l volts
17 volts kg/l volts
18 volts kg/l volts

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Diagnostic Report Battery Technology

8. Action to be taken if one or more blocks are defective

8.1 Replacing the battery due to age Note:
– Never connect together batteries of different
Period in Charging types, e.g. low-maintenance, maintenance-
Battery free, gel, bonded fabric, grid plate, armour-
service cycles
plate, etc.
6 V, 160 Ah 12 months 200
12 V, 60 Ah 6 months 100 – Never connect together batteries of different
manufacture or type designation.
When the battery has reached the end of the – Never connect together batteries of differing
above-mentioned period in service or the capacity.
maximum number of charging cycles, it is no
longer worthwhile replacing one battery block – Never charge new blocks connected in series
with another. It is recommended that the whole with old blocks, otherwise the new blocks will
set is replaced. be overcharged and destroyed.
– Always charge blocks with differing charge
states individually.
8.2 Matching the charge state
– If the charger has sufficient capacity ( > 30 A),
of different blocks
the blocks can be charged in parallel. First of
all connect the battery to the charger and only
If the battery has reached neither the period in then connect further batteries. It is very
service nor the number of charging cycles shown important to comply with the information
above, then it is indeed worthwhile replacing a provided by the manufacturer of the charger.
defective block. The following action must
however be taken to match the charge state of – Only blocks in good condition may be charged
the individual blocks to one another again. in parallel. Blocks with an off-load voltage
below 6.0 V / 12.0 V should not be charged in
– Remove the defective block. parallel.
– Charge the remaining blocks and the new – The charging time is approx. 48 hours.
one individually! It is very important that the
prescribed charger is used for this purpose
(see Page 32 and 33). A laboratory power
supply unit can be used for 6-volt blocks
(minimum specifications: 0–30 V and 0–5 A).
– If a laboratory power supply unit is used, the
charging voltage should be set to exactly
7.14 volts (6 V block) or 14.28 volts (12 V
block). The charging current should not
exceed 13–20 A (for 160 Ah).
– When the charging process has ended, the
current should have dropped to below 1.2 A
(160 Ah) or 0.5 A (60 Ah).

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Battery Technology Diagnostic Report

Matching charge states by connecting blocks in parallel

8.3 Attempting to repair a sulphated /

totally discharged battery
A battery that has failed is not necessarily defective. permitted to increase the voltage at the start of
It may have been insufficiently charged and charging for a short period.
become sulphated. Such batteries can usually be A capacity test (see Page 28) should be
refreshed by charging them at a constant current performed in accordance with DIN 43 539 Part 3
of approx. 1.6 A (6 V/160 Ah) or 0.6 A (12 V/60 Ah) when charging has ended. If the battery capacity
for approx. 10–14 days. is more than 80 % of its nominal capacity, it can
The voltage at the end of the charging process be taken back into service. Otherwise, the battery
should not exceed 2.4 volts/cell. Only when is defective and must be disposed of
sulphating has reached an advanced stage is it appropriately.

Matching charge states by connecting blocks in series

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Diagnostic Report Battery Technology

9. Battery defects c) Manufacturing defects

Batteries can fail for the following reasons: Typical indicators are:
a) Age, a large number of completed charging – the no-load voltage is significantly lower than
cycles or permanent overcharging the prescribed value, and the difference can
already be measured after 3 hours.
Typical indicators are:
the battery fails after only a short period in
– the battery fails the load test, i.e. voltage use (less than 6 weeks).
quickly breaks down under load.
Cause: internal short-circuit between cells
– the battery fails the capacity test, i.e. significant,
irreversible loss of capacity. – the battery voltage drops off suddenly when
under heavy load.
– if the vent plugs are opened, the active
material appears to be a sponge-like mass after a load has been applied for a longer
and as it becomes older, the material dries period, the intercell connectors and/or the
out, becomes brittle and drops off the grid terminal posts have become noticeably hot.
plate. Cause: bad contact between the intercell
connectors or terminal posts.
Important: The age of a battery can not be
judged by the no-load voltage. You will find further information on carrying out
repairs to battery chargers in Service Information
1998-035.

b) Sulphating
Typical indicators are:
– the battery voltage drops off prematurely
under load.
– if the vent plugs are opened, a white coating
can be seen on the negative and positive
plates. The white coating on the positive
plate is more prominent than the coating on
the negative plate, and in an advanced state
it will be crystalline, i.e. very hard. When it has
reached this stage, the coating caused by
sulphating can not be removed.
– When charging first starts, the voltage rises
to higher than 7.2 V / 14.4 V.

Important: Sulphating is caused when the

battery is consistently undercharged or if it
has been stored for a long time without
receiving a compensation charge. The loss
of capacity can be reversed by carrying out
the special charging procedure explained
in item 8.3.

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Battery Technology Diagnostic Report

10. Battery monitoring with deep-discharge protection

All machines which are battery operated have a tion). If the deep-discharge protection has been
battery monitoring device on the instrument wrongly set, the machine will switch off either
panel (pointer instrument or LED indicator). If too early or too late. If the former case, the
the red LED lights up, the machine is switched length of time the machine is in use is cut short
off. This stops the permissible capacity discharge and in the latter case the battery will be in a
from being exceeded (deep-discharge protec- deep-discharge state and thus damaged.

Unit Battery monitoring Red LED

(deep-discharge protection) lights up at
the following voltage (volts)
KSM 690 Profi Pointer instrument, no deep-discharge
protection Red area £ 10.5
KSM 750 BAT Pointer instrument, no deep-discharge
protection Red area £ 10.5
KSM 750 BAT Profi ≤ 22.3 ± 0.1
KSM 950 BAT ≤ 20.5 ± 0.2
KMR 1200 BAT ≤ 19.5 ± 0.2
KMR 1050 BAT ≤ 32.5 ± 0.2
KMR 1250 BAT ≤ 20.5 ± 0.2
BD 450 BAT Indicator light blinks at £ 20.5
No deep-discharge protection
BR/BD 530 BAT ≤ 21.5 ± 0.2
BR/BD 550 BAT ≤ 21.3 ± 0.2 ¹)
≤ 22.7 ± 0.2 ²)
BR/BD 700 BAT ≤ 32.0 ± 0.4 ¹)
≤ 34.0 ± 0.4 ²)
BR 900 BAT ≤ 19.5 ± 0.2
BR/BD 1000 BAT ≤ 31.5 ± 0.5
¹) Battery, low-maintenance
²) Battery, maintenance-free

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Diagnostic Report Battery Technology

11. Setting the deep-discharge protection

Correct setting of the deep-discharge protection
is of crucial importance for its proper functioning
and for protecting the battery from becoming
damaged.

There are two settings which have to be taken

into account and carried out on the printed
circuit board of the unit concerned:

1. Setting of the unit-type, e.g. BR or BD

2. Setting of the battery-type, e.g. maintenance-

free or low-maintenance

On the printed circuit board of the unit concerned

there are two marked DIP switches with which
the appropriate settings can be made.

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Battery Technology

Keywords and definitions

The following list contains definitions of terms Operational capacity
associated with DIN 40 729 that have been
The operational capacity is the stored volume
used in this manual.
of current (Ah) required to match a pre-defined
(quantified) application. In the case of lead-acid
batteries that are discharged over a period of 5
Lead-acid battery
hours, only 80 % of the nominal capacity is
A lead-acid battery is an energy-storing device usable.
that has positive and negative electrodes. When
the battery is in a charged state, the positive
active material consists of lead (IV) oxide (PbO2) Block battery
and the negative active material is lead sponge
A block battery consists of several cells linked
(Pb). In a discharged state the active material
together in one container.
contains lead (II) sulphate (PbSO 4). The
electrolyte consists of diluted sulphuric acid
(H2SO4) which is transformed during the reaction Useful life
process.
This is a period of time during which a battery
fulfils its intended purpose with regards to its
Equalising charge ability to supply energy. To achieve this, the
battery must be properly serviced and the load,
An equalising charge is a pre-defined additional
temperature and discharge cycles must not
charge that is applied to a battery in order to
exceed the prescribed limits (see DIN 40 042,
ensure that the active material in all cells is
Issue June 1970 Table 3.1.1 and 3.1.2).
entirely converted back into its original state.
Depending upon the method of charging and
the prevailing operating conditions, it is not Electrolyte density
always possible to ensure that the full-charge or
intermediate-charge cycle is completed. It is The electrolyte density is the concentration of
therefore necessary – for example, at weekends acid within the electrolyte solution inside a
or after a battery has been totally discharged – battery cell. It affects the capacity, voltage, and
to apply an equalising charge to maintain the internal resistance of a cell as well as its ability
nominal capacity and stabilise the voltage. to discharge spontaneously.

Battery operation Energy throughput rate

Battery operation refers to when a load source This is the capacity throughput rate (Ah/t)
or consumer is powered solely by batteries. multiplied by the average discharge voltage
under working conditions.

Battery nominal current

Discharge end voltage (US)
See n-hour discharge current.
The discharge end voltage is a pre-defined
voltage level, below which a battery should not
Battery voltage fall, at the end of a discharge cycle that has
been performed in accordance with the assigned
The battery voltage is the potential difference
current.
that can be measured at the output terminals for
whatever operating state the battery is in at the
time. Compensation charge
A compensation charge is a constant-voltage
charge of unlimited duration which has the
purpose of maintaining a particular charge state
or keeping the battery fully charged.

47
 Battery Technology

Keywords and definitions

Voltage at begin of gassing (UG) cells tend towards a final value (no-load voltage):
UO (V/Z) = acid density (kg/l) + 0.84. For example,
This is a temperature-dependent charging
with an acid density of 1.27 kg/l, the no-load
voltage above which level a battery begins to
voltage UO = 1.27 + 0.84 = 2.11 V/cell.
create noticeable amounts of gas (hydrogen
and oxygen escape in the form of bubbles).
Note: UG = 2.4 V/cell for lead-acid batteries Secondary charge
at +30 °C
The secondary charge phase follows
immediately after the primary charge and serves
to ensure that the active material in all cells is
Grid plate
entirely converted back into its original state.
The grid plate is either a positive or negative
electrode. The difference lies in the type of
active material that has been inserted into the Water used for replenishment
grid. The active material is held in place by this
The water used for topping up batteries is
conductive grid (material holder).
purified water that conforms to DIN 43 530 Part
4 (currently in draft form). It can be either
distilled or demineralized.
Primary charge
The first phase in the battery charging process
during which the battery is charged to within at Nominal capacity (Cnom)
least 95 % (maintenance-free) or 80 % (low
The nominal capacity is the amount of electricity
maintenance) of its full-charge state.
which can be drawn from a battery that is
discharged under nominal conditions (discharge
current and time, end voltage, temperature,
Capacity throughput rate (Ah)
density and level of electrolyte). The nominal
This is the volume of electricity (Ah) per unit of capacity Cnom is laid down by the manufacturer.
time that is drawn from the battery during the
Note: The following parameters for traction
charge/discharge cycles.
batteries are commonly used in DIN
standards and IEC publications:
Charge/discharge cycle Cnom = C5
The sequence of charging and discharging a at Tnom = +30 °C and US = 1.70 V/cell.
cell or battery.

Nominal voltage
Charging factor
The nominal voltage for a cell is a fixed value.
The charging factor is the relationship between
Note: The value for lead-acid batteries is 2.0 V/
the current required to achieve a full charge and
cell.
the amount of current discharged previously.

Nominal temperature (Tnom)

Charge state
The nominal temperature is the electrolyte
The charge state is defined as the relationship
temperature for a particular type of battery and
between the volume of current (Ah) stored in
is pre-determined in conjunction with the
the battery at any point in time and its specified
corresponding nominal capacity.
capacity for n-hours (Cn ).

Capacity for n-hours (Cn )

No-load voltage (UO )
Every battery has a capacity that equates to the
The no-load voltage is the voltage across a cell
time required to discharge it. The subscript n
or battery when this is not subjected to any form
indicates the discharge time in hours (e.g. C5 =
of load. When the charge or discharge cycles,
5-hour capacity for traction applications).
which consist of the diffusion or polarisation
processes at the electrodes, have ended, the

48
Battery Technology

Keywords and definitions

Discharge current over n hours (In ) Polarity reversal
The n-hour discharge current corresponds to Polarity reversal takes place in the individual
the n-hour capacity: cells in a battery as a result of excessive
In = Cn , e.g. I5 = C5 discharging (total discharge).
tn 5h
Full charge
Armour plate / tubular plate A battery is said to have been fully charged
when its active material has been entirely
An armour plate is a positive electrode in lead-
converted back to its original state.
acid batteries and is constructed from a row of
adjacent tubes that are made of insulating
material but allow electrolyte to pass through.
Low-maintenance batteries
The lead splines inside the tubes provide
mechanical stability and act as the electrical This type is also referred to as a closed, wet or
conductor. The space between the lead spline liquid-electrolyte battery. They can be recognised
and the tube is filled with active material. Positive by vent plugs which can be opened. The plugs
armour plates are used in conjunction with are opened in order to top up the battery with
negative grid plates. In North America and the water (either distilled or demineralized in
UK armour plates are usually referred to as accordance with DIN 43 530 Pt 4).
tubular plates. Before this type of battery is used for the first
PZS = wartungsarme Panzerplattenbatterie = time, it must be filled up with electrolyte with the
low-maintenance armour-plate battery correct acid density (1.28 kg/dm3). In addition
they must also be charged before they can be
PZV = wartungsfreie Panzerplattenbatterie =
used.
maintenance-free (sealed) armour-plate
battery Only devices that have been approved by the
battery manufacturer should be used for
charging these batteries.
Off-load voltage Failure to comply with this information could
The off-load voltage occurs when the effects of result in the destruction of the battery and any
the last charging or discharging cycle have subsequent warranty claim will rejected.
subsided. The off-load voltage occurs after at The level of electrolyte must be regularly
least 15–20 hours in the case of maintenance- checked while the battery is in service.
free batteries and after approx. 1 hour for low-
maintenance batteries.
Maintenance-free batteries
Partial charge (intermediate charge) This type is also referred to as a sealed, dry or
gel battery. They can be recognised by plugs
A partial charge is an incomplete charging cycle which can not be opened. They do not require
where the active material is not entirely topping up with water. They are supplied in a
converted back to its original state.
charged state and ready for immediate use.
Only devices that have been approved by the
Total discharge battery manufacturer should be used for
charging these batteries.
A total discharge occurs when a battery is
discharged beyond its pre-determined Failure to comply with this information could
operational capacity. result in the destruction of the battery and any
subsequent warranty claim will rejected.

Overcharging
Overcharging takes place when a battery
continues to be charged after the active material
has been entirely converted back to its original
state. It is accompanied by significant gassing.

49
 Battery Technology

Keywords and definitions

Efficiency
During the process of charging, electrical energy
is converted into chemical energy. The opposite
applies to discharging. The losses that result in
the process, for example due to the active
resistance of the battery or gassing or variations
in voltage, determine the efficiency of the charge,
i.e. the energy.

Energy efficiency
(Efficiency of the current, volume of current)

h E
=
energy that has been drawn [Wh]
energy to be replenished [Wh]

Charge efficiency

h L
=
volume of current that has been drawn [Ah]
volume of current to be replenished [Ah]

Intermediate charge
See Partial charge.

Full cycle
A full cycle consists of one entire discharge/
charge process.

General technical specifications* low-maintenance maintenance-free

Nominal temperature TN (°C) 30 30
Gassing voltage UG (volts/cell) 2.4 2.4
Off-load voltage at total discharge (volts/cell) < 1.9 < 2.0
Primary charging current (A/100 Ah) 13–20 13–20
Secondary charging current (A/100 Ah) 4–5 0.6–1
Equalising charge current (A/100 Ah) 5 1
Compensation charge (volts/cell) 2.25 2.25
Duration of equalising charge to achieve
10–20 10–20
desulphation (days)

* Exact specifications should be obtained from your battery supplier.

50