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Lead-Acid Starter Batteries in Systems Usage Information

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Lead-Acid Starter Batteries in Systems Usage Information Batteries Association ZVEI information leaflet No. 28e Edition October 2017 Lead-acid starter batteries in systems Usage information Preliminary note: This information leaflet aims to help to choose batteries and develop design solutions and operating manuals by providing general information on the usage of lead-acid batteries in vehicles, which extend beyond the relevant standard specifications. This information serves as a recommendation only, and not as a substitute for the battery user’s responsibility to make appropriate decisions. By pooling all gained experience to date, however, it should make the decision easier. Contents 1. General .............................................................................................................................................. 2 2. Mechanical loads.............................................................................................................................. 2 2.1. Battery installation................................................................................................................. 2 2.2. Vibration stress...................................................................................................................... 3 3. Thermal stress..................................................................................................................................3 3.1. Battery temperatures............................................................................................................. 4 3.2. Possible measures regarding thermal loading ...................................................................4 4. Electrical loads .................................................................................................................................4 4.1. Electrical battery integration into the vehicle .....................................................................4 4.2. Battery voltage....................................................................................................................... 5 4.3. Battery currents ..................................................................................................................... 6 4.4. Limits of cyclical loading ......................................................................................................6 5. Installation space of the battery......................................................................................................6 5.1. Battery ventilation.................................................................................................................. 6 5.2. Protecting against corrosion caused by battery acid......................................................... 7 5.3. Electrostatic discharge (ESD)............................................................................................... 8 5.4. Splashing water ..................................................................................................................... 8 5.5. Direct light exposure (UV).....................................................................................................8 5.6. Battery environment.............................................................................................................. 9 5.7. Battery installation direction in the vehicle......................................................................... 9 5.8. Signs and warnings............................................................................................................... 9 6. Regulations for interconnecting batteries...................................................................................... 9 6.1. Batteries connected in series ............................................................................................... 9 6.2. Parallel battery connections .................................................................................................9 6.3. Combined series and parallel connections:........................................................................9 7. Repair and maintenance information ............................................................................................. 9 7.1. Frozen batteries ..................................................................................................................... 9 7.2. Installation and dismantling batteries.................................................................................. 9 7.3. Checking and correcting electrolyte levels ......................................................................... 9 7.4. External charging ................................................................................................................ 10 7.5. External start-up .................................................................................................................. 10 This leaflet was prepared by the Working Group Starter Batteries of the ZVEI – German Electrical and Electronic Manufacturer’s Association 1. General fixed in, the tray must be 2.1.4 One-piece cover as per designed in such a way so as to EN 50342, parts 2 and 4 Lead-acid batteries as defined enable the multiplied battery by this recommendation fulfil weight resulting from strong These European standards their function during engine vibrations or a crash to be describe batteries with flat start-up, when supplying power absorbed. covers. In these batteries, the to the on-board electrical end terminals, and in some system, and while smoothing the The various battery types enable cases also the cell cap stopper, system’s voltage. A series of different installation options: sit beyond the cover. Typical instructions must be followed fastening devices include full when using lead-acid batteries frames or brackets with tie rods to ensure customer satisfaction running vertically to the battery’s 2.1.2 Base hold-down bars as transverse axis. The fastening in terms of maximum product per EN 50342-2 reliability. These instructions are devices must be mechanically based on the battery’s This European standard stable, and screwed snugly into dependence on mechanical, describes base hold-down bars the base plate. The fastening thermal and electrical influences, running around the long and devices must be designed in and take into account safety front sides. These standardised such a way so as to absorb any aspects. base hold-down bars have a forces applied to the battery. clearly specified profile. They Additional protection against This information leaflet contains also have standardised beading slipping sideways is required. recommendations for safe at set locations. The structural See 2.1.5 for the permitted handling of these batteries. It elements required to affix the clamping forces. does not replace the industrial battery, such as terminal strips, work instructions issued by the clamps etc., are responsible for OEM, the usage instructions positioning the battery in the 2.1.5 Permitted clamping forces provided by the vehicle tray, fastening it down and protecting it from sliding to the The battery cases are generally manufacturer, or the vehicle made from polypropylene. operating manual. side. The fastening devices must be mechanically stable, and EN 50342-5 establishes the requirements for materials, Following a wide range of screwed snugly into the base plate. The fastening devices and battery boxes and covers. One requirements, optimised of the properties of batteries are used for special elements must be designed in such a way so as to absorb any polypropylene is that it yields usage conditions in addition to under loads. This means that it standard batteries. Special forces applied to the battery. Slide protection is ideally takes only a change in usage conditions include high temperature to significantly mechanical loads, high thermal provided using lugs which protrude into the base hold- reduce the clamping force loads and specific electrical applied by initial fastening. Even loads. Particular attention must down bars’ beading. The fastening devices must be able high clamping forces will not be paid to the safety-related change this, resulting in plastic properties. to prevent any damage to the battery. See 2.1.5 for the deformation in the case walls. permitted clamping forces. When fastening the battery The installation location, using the base hold-down bars, operating conditions and choice a certain degree of plastic of battery must all be in tandem deformation in the base hold- with one another. These 2.1.3 Covers as per down bars is required in order to guidelines are designed to help EN 50342-2 permanently fasten the batteries. with this and explain the finer This European standard Excessive deformation destroys details. describes batteries with covers, the case. For this reason, whose tops have defined bottom-bar deformation should recessed sections on both of the not exceed 15% of the bottom 2. Mechanical loads long sides. The resulting section bar’s height during assembly. is ideal for top-down fastening. 2.1. Battery installation Typical fastening devices NOTE: Bottom-bar battery include brackets running fastening is a hyperstatic system 2.1.1 The battery tray crossways to the battery with tie to which the construction rules of The battery tray is the rods. The fastening devices mechanical engineering cannot designated battery receptacle on must be mechanically stable, be applied in relation to plastic the vehicle. It must be and screwed snugly into the deformation. The following mechanically stable, and base plate. The fastening structural features
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