Maintenance Guide

1. Visual Inspection: Check battery age or length of service if available.
Inspect battery for damage - when physical damage to the battery container or
terminals is present, replace the battery. Be sure no open ame or spark is near
while the battery’s vent caps are removed from the battery. If none, check the
battery’s cell electrolyte levels. Fluid levels should be above the top of plates in all
cells, and no higher
than the top of the
uid level indicator:
If the battery is
sufciently lled
with electrolyte –
proceed to step
two. If the top of the battery’s plates are not covered with liquid, add water, replace
vent caps and place the battery on charge.
2. Specic Gravity Inspection: Hydrometer reading of all cells should be at
least 1.235 and show less than 50 points difference between high and low.
More than 50 points difference: replace the battery. Less than 50 points, but some
cells read less than 1.235: recharge the battery. Replace the vent caps during
recharge. Charge the battery using a properly matched automatic charger until
all cells measure a specic gravity of 1.275 to 1.280. If charging won’t bring up
specic gravity, replace the battery.
Troubleshooting
Specific
Gravity
State of
Charge Level
100%
75%
50%
25%
Discharged
1.280 or Greater
1.235 - 1.240
1.190 - 1.195
1.150 - 1.175
1.125 or Less
Hydrometer
Float
Example:
BATTERY
WORN OUT
READY TO
LOAD TEST
VARIATION
55 POINTS
VARIATION
25 POINTS
CELL 6 - 1.200
CELL 5 - 1.210
CELL 2 - 1.215
CELL 1 - 1.240
CELL 3 - 1.240
CELL 4 - 1.255
1.300 1.250 1.200 1.150
CELL 6 - 1.225
CELL 5 - 1.230
CELL 2 - 1.235
CELL 1 - 1.240
CELL 3 - 1.245
CELL 4 - 1.250
State of
Charge Level
100%
75% - 100%
50% - 75%
25% - 50%
0 - 25%
0%
12 Volt Battery
Open Circuit Voltage
12.6 or Greater
12.4 - 12.6
12.2 - 12.4
12.0 - 12.2
11.7 - 12.0
11.7 or Less
6 Volt Battery
Open Circuit Voltage
6.3 or Greater
6.2 - 6.3
6.1 - 6.2
6.0 - 6.1
5.95 - 6.0
5.95 or Less
Chart Assumes a Fully Charged Gravity of 1.280.
3. Open Circuit Voltage and Electrical Load Test: Battery open circuit
voltage is an effective indication of battery state of charge.
Determine the approximate state of charge from the chart at the right.
Electrical load testing is an effective troubleshooting technique for identifying
batteries with internal defects – but it is not an approved method for measuring
deep cycle battery capacity. For this reason Zoeller recognizes load test results as
useful only for identifying batteries having bad cell conditions.
Batteries with less than 75% state of charge should be charged before an
electrical load test is applied to the battery. When load testing batteries, remove
all battery cables, disconnecting the negative cables rst. Make sure the battery
terminals are free of corrosion and dirt.
Using a carbon pile load tester, apply a 50 to 75 ampere load for 15 seconds;
remove the load. Refer to the chart at the right to determine the minimum passing
voltage.
A common procedure for troubleshooting battery performance
involves a three-point procedure:
Battery Voltage Under 15 Second Load
State of Charge 12 Volt 6 Volt Specic Gravity
100% 12.66 6.33 1.280
75% 12.00 6.00 1.235
If the test voltage is above the minimum, return the battery to service.
If test voltage is below the minimum, replace the battery.
FM2484
1012
Supersedes
0108
MAIL TO: P.O. BOX 16347 • Louisville, KY 40256-0347
SHIP TO: 3649 Cane Run Road • Louisville, KY 40211-1961
[phone] • 1 (800) 928-PUMP • FAX [phone]
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www.zoeller.com
Product may not be exactly as illustrated.
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