Battery related failures in NBN Batteries
This occurs when a battery has prematurely failed due to extreme conditions of use commonly found in Australia’s harsh climate. When this happens the best course of action is replacement. For an replacement NBN battery on site we recommend a call out service.
NBN Battery failures include:
Low electrolyte levels expose the busbar and ultimately the upper portion of the plates that can cause irreversible sulphation, and can accelerate corrosion. The low electrolyte levels can be the result of lack of battery maintenance, or as a result of overcharging where fluid is lost through gassing. As an additional problem, the acid concentration in the battery from lower electrolyte levels can cause increased corrosion of the remaining ‘wet’ part of plates. Forklift batteries with higher electrolyte volume above the plates assist in minimising these problems, and ensuring batteries are regularly maintained when operating in harsh conditions will also prolong NBN battery life.
High operating temperature. Harsh Australian operating conditions, and increasing vehicle under bonnet operating temperatures, can cause early NBN battery failure through a number of areas. These conditions contribute to corrosion of the positive plate, grid growth which can result in a short circuit, and loss of plate active material.
Vibration effects. This can cause physical damage to battery components and often sudden failure of the battery.
Vibration damage can include:
– Loss of active material from the plates, resulting in a loss of battery charge and possible short circuits.
– broken or cracked grid frames, causing short circuits; usually causing separator damage.
– perforation of the separator envelopes at the bottom where the plates sit in the battery case. This can result in short circuits.
Overcharging your NBN battery. Where the charging system has been operating at a higher than normal voltage, the battery is subjected to virtually continuous charging. This can result in faster grid corrosion, loss of plate active material, loss of electrolyte, plate growth and eventually disintegration of the positive plate.
Undercharging. This can occur when the vehicle voltage charging system is too low to fully recharge the battery. The result is a loss of charge and irreversible sulphation of the battery.
Plate or Grid Related Corrosion
Grid corrosion of the Positive plates within a battery is a normal ‘end of battery life’ condition that is commonly caused due to higher operating temperatures, overcharging or loss of electrolyte fluid. Of the positive and negative plates within a battery, it is the positive plates where the grid metal can completely oxidise and disintegrate due to these operating conditions. Different alloys added to the positive grid lead can have an affect on the corrosion rate. Antimonial lead grids generally have a higher corrosion resistance than calcium lead grids, and along with higher volumes of electrolyte above the plates, can help overcome this problem, allowing batteries to operate more successfully in Australia’s harsh conditions.
Soft Positive Plate Material (“mushy plates”). This is a condition usually resulting from high operating temperatures or overcharging. Often, both conditions may have occurred.
Sulphation. This occurs when a battery stands in a partially or fully discharged state for long periods of time, or is continually undercharged. As a result of these conditions the active lead material on the plates becomes lead sulphate which also hardens the plates. Depending on the length of time the battery has been in this condition, the sulphation may be irreversible. In addition, if the electrolyte level in the battery is low, the exposed part of the plates will become inactive and sulphated. Therefore batteries with higher electrolyte levels will go a long way to reducing problems due to sulphation and assisting longer battery life.
NBN Open Circuit Battery:
Including causes such as:
Broken cell to cell connection. This is where there has been a complete failure of the intercell weld. Weld quality is critical for reliable battery performance and good working life. This problem is largely minimised by manufacturers like Century Yuasa Batteries and other leading manufacturers, due to accredited quality assured manufacturing processes.
A broken busbar. This type of failure can be caused by excessive corrosion of the busbar due to low electrolyte level in the battery. Extensive overcharging and/or elevated operating temperatures can also lead to accelerated corrosion of the busbars leading to breakage and and open circuit. Batteries with the capacity for higher electrolyte levels will help to ensure a longer battery life.
Short Circuit in NBN Battery
Including causes such as:
Plate to busbar short circuits can result from bent plates contacting the busbar, or corroded positive plates which have grown upwards, contacting the busbar and causing a short circuit. This fault can be age related and can be a normal ‘end of life’ condition. It can also be a result of overcharging, cycling or elevated operating temperatures.
Plate to plate short circuits occur when positive and negative plates make contact causing short circuit, resulting in battery failure. Vibration can cause the plates to wear or pierce the separator material leading to a short circuit. Century Yuasa Batteries utilise strong Polyethylene Envelope separators which makes them less susceptible to this problem.
Worn out or ‘End of Life’ conditions on NBN batteries The normal ‘end of life’ condition in a battery is when one or more cells cease functioning due to the positive plate grid having oxidised (corroded) and finally collapsing. Operating temperatures have a definite effect on battery life, and high temperatures will accelerate these ‘end of life’ conditions.
Disclaimer: Century Yuasa Batteries Pty Ltd nor Balmain Batteries does not take any responsibility for any inaccuracy of the information contained herein.