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Common Faults dry car battery charge, and Analysis
Faults Phenomena Causes Ascription of Responsibility
1.
Overcharge		 一.Overcharge
1.Battery case turns dark.
2.Clapboard becomes black.
3.Electrolyte turns red or level of electrolyte goes down.
4.Active materials of pole plate fall off severely.
5.Capacity table points to red area.
6.It is difficult to start vehicles, hot batteries.
7.Proportion of electrolyte is higher than standard value.
8.Positive plate-grid of batteries is rotten and broken.
1.Voltage regulator for vehicles has a high set point (charging voltage of 12V auto batteries is 13.8-14.4V)
2.Charging voltage regulator of vehicles is out of control.
3.Charge in heavy current for a long time deliberately. (charging voltage of 12V motorcycle batteries is 14-14.5V, half for 6V batteries)
 Inappropriate usage of customers
2.Overdischarge 1.Open circuit voltage is below 10V (12V batteries. Half for 6V batteries)
2.Proportion of electrolyte is below 1.15.
3.Surface of positive plate is yellow or yellow-white (chocolate brown commonly); pole plate is bent so severely (that batteries have short circuit or broken plate-grid).
4.Active materials of positive and negative plate are too hard to be broken easily.
5.Users say batteries do not store electricity.
1.Continue to use batteries in undercharge.
2.Car power line short-circuits.
3.Electric part of vehicles is not turned off after usage.
4.Voltage of car body charging regulator
is too low (13.8 below)
5.Placed away for a long time without timely charge.
6.Users add electric liquid of above-norm impurity into batteries, or put drinking mineral water or water from pond, river, well, brook, field or lap into batteries while usage, which cause severe self-discharge.
Inappropriate usage of customers
3.Inappropriate liquid injection After complete charge, proportion of electrolyte is too high or too low. Users say batteries do not store electricity. 1. Proportion of priming is too high (exceed 1.290 25℃ or 260 25℃).
2.Liquid level goes down during usage, and sulphuric acid liquid or impure water (drinking mineral water or water from pond, river, well, brook, field or lap) is added in. 		Inappropriate usage of customers
4.Short circuit 1.Voltage is around 10V or 10V below.
3.In six simple grids, proportion of simple grid electrolyte is clearly too low.
4.Users say some simple grid has high temperature while charging, bubbles and does not storage electricity after charge.		 1.Twisted poles make clapboard break.
2.Lead shot falls into batteries.
3.Broken clapboard.
 Inferior manufacturing, product returnable.
4.Conductive substances fall into batteries due to inappropriate usage.
5.After long-term usage, batteries nearly use up its service life; active materials of pole plate fall off severely.		 Inappropriate usage of customers
5.Circuit break 1.Checking by voltmeter, voltage of positive and negative terminal is 0V or ordinary; proportion of electric liquid is normal or close to normal.
2.While discharging, ammeter points in an abnormal unsteady manner or does not have current.
3.While discharging by capacity meter, plenty of bubbles emerge from the circuit break place.
4.If the circuit break is caused by broken terminal poles, click the broken part and it flops; broken terminal heats up while discharging (compare the two terminals)
5.Users say that the batteries could not charge or discharge.		 1.Terminal poles and pole assembly are not burnt together well.
2.Pole assembly has not fallen onto the bottom of batteries shell. After applying for some time, poles are broken. 		Inferior manufacturing, product returnable.
3.Exterior short circuit (scar molten may leave on terminal poles of some batteries.)
4.long time heavy-current discharge due to engine failure.
5.Long time heavy-current starting discharge because of engine failure.		 Inappropriate usage of customers
6.Undercharge 1.Voltage is below 12V (half for 6V batteries).
2.Proportion is below 1.22.
3.Difficult start-up, dim light, weak trumpet, abnormal usage of other electric apparatus in the car, such as acoustics. 		1.Charging voltage regulator of cars has a low set point, or failure of charging system.
2.Load of vehicles is larger than charging capacity.
3.Slight short circuit.
4.Engine failure.
5.Starter failure.
6.Bad contact of terminal wires. 		Inappropriate usage of customers
7.Fail to feed water timely Liquid level is under “lower limit of liquid level” or below upper surface of pole plate. Fail to feed pure water to upper liquid surface line. Inappropriate usage of customers
8.Leakage 1.No scar clearly caused by bump, knock or press on battery shell or terminals; but batteries leak.
2.Users are responsible for battery damage. 		Bad joint of shell and cap.

Inferior manufacturing, product returnable.
Transport, installation or other accident of users. Users are responsible
9.Reversal 1.Obvious reduce of battery capacity.
2.After new batteries are refilled with liquid, open circuit voltage is only around 8V (excellent seal, within storage term)		 Assembly problem Inferior manufacturing, product returnable.
3.Reversal of batteries occurs after normal usage for some time. Because of overdischarge, some simple grid is charged by other grids after discharging completely. Customers’ responsibility. Inappropriate maintenance.
4.Positive and negative terminals turn into contrary colors.
5.Positive and negative bus rods and pole plates turn into contrary colors. 		Users mix up polarity of batteries while charging. Customers’ responsibility. Inappropriate maintenance.
10.Battery exceeding shelf life Do not serve, but exceed “Three Guarantees” term regulated by the factory. Dry-load auto, motorcycle and VRLA batteries exceed storage term of one year; auto batteries with liquid exceed storage term of half year (note: a small part of products rejected by customers passed sampling inspection. Their storage term is reset according to number printed for the second time.) Customers' responsibility
11.End of service life 1.Active materials at the bottom of battery shell fall off severely.
2.Battery shell turns dark and looks worn out.
3.Clapboard turns black; electric liquid is thick while charging.
4.Plate grid is erosive.
5.Users say batteries have bad charging effect and can not start cars easily or start cars at all. 		End of service life. End of service life

Common Faults VRLA batteries, and Analysis

Faults Phenomena Causes Ascription of Responsibility
1.Overdischarge 1.Voltage of 2V batteries is below 1.8V (0-1.5V normally)
2.Voltage of 12V batteries is below 10V; voltage of 6V batteries is below 5V.		 1.voltage is below scope of instruction demand; batteries are short of electricity.
2.No charge for long time.
3.Supply current of recycle batteries is not sufficient each time.
4.Discharge according to certain current; continue discharging till final voltage; after discharging fail to charge timely or sufficiently.
5.Storage term is too long. 		Customers’ responsibility. Inappropriate maintenance.
2.Overcharge 1.Each simple grid of battery shell expands and clearly transforms (slight expansion and transformation during usage is normal.)
2.Battery capacity turns smaller (electric liquid turns dry.)
3.Base of terminal poles pops up acid.
4.Voltage of a certain battery assembly is not evenly distributed. 		1.Floating voltage exceeds standard value of instructions.
2.Environment temperature is above 45℃, but floating voltage is not reduced according to requirements (take 25℃ as an example, for every 1℃ increase of environment temperature, voltage reduces 3mV.)
3.Battery charger is out of control or regulated wrongly, in this case, charge current exceeds specified value for long time. 		Customers’ responsibility. Inappropriate maintenance.
3.Short circuit (seldom) 1.In one battery assembly, voltage of other batteries is normal; only one simple grid is 2V smaller, (for example, voltage of 12V batteries is 10-10.8V, 6V batteries voltage is 4.-4.3V, and 2V batteries 0V).
2.After balanced charging, voltage of simple grid still can not meet rated voltage of 2V (12V batteries could not reach 12V above, 6V batteries could not meet 6V above, and 2V batteries could not reach 2V above), and one simple grid short-circuited heats up severely. 		1.Worn or broken clapboard.
2.Lead shot falls into batteries. 		Inferior manufacturing, product returnable.
4.Leakage of batteries liquid 1.Shell or cap of batteries is broken because of bump or knock. Shock during transport, convey, installation or other accidents. Find out the person responsible
2.Leakage of poles bonnet of batteries Shell transformation and leakage due to heavy-current long-time charge. Customers’ charging problem
Leakage of poles and valve caps while appearance is good. manufacturing quality, product returnable.
Poles leakage caused by severe twist or shock of poles Inappropriate operation of customers
3.acid leakage of batteries shell or joint place Untight heat seal or bonding shell and cap. Inferior manufacturing quality, product returnable.
5.Worn outlook Broken pole or severe damage to battery appearance Inappropriate wiring, or poles are knocked down in accidents and appearance is broken consequently. Customers' responsibility
Caused by transport or convey Find out person responsible
6.Valve fault 1.Some simple grid of batteries expands severely or even breaks the shell. Cap and base of valve connect abnormally on the top, and batteries could not exhaust (our factory have not seen this for years) Inferior manufacturing quality, product returnable.
2.After storing for some time (2-6 months), open circuit voltage or closed circuit voltage of some batteries is clearly lower than other batteries (2V batteries is 2V below, 6 V batteries is 5.5V below, and 12V batteries is 11V below). When opening cap of batteries, superface center of one or two valve caps is not sunken (there should be hollowed surface). 1.Too loose joint of valve cap and valve base, which lead to inferior seal of some simple grid of batteries.
2.Interior wall of value cap or exterior wall of valve base has impurity, and some simple grid is not sealed well. All simple grids without good valve seal condition may let oxygen enter batteries and cause cathode oxidation and consequently self-discharge; and this simple grid can easily lose battery capacity because of water lost.		 Inferior manufacturing quality, product returnable.
7.Self-discharge After complete charge (according to production date), batteries that lose capacity lower than or equal to 40% in 25±5℃ environment for 6 months are in accordance with Japan industrial specification "JISC8707-1992" and domestic "JB/T8451-1996" standard. When batteries are stored for a summer to six months, if power capacity left in 10 hours is no less than 50%, it means that environment temperature is higher than 25℃ and it is summer; therefore, as high as 50% self-discharge is normal. Normal
While storing for 6 months in temperate zone, batteries discharge capacity is less than 50% in 10 hours. While storing for 6 months in tropical zone, batteries discharge capacity is less than 40% in 10 hours. Manufacturing quality problem or around 40℃ high temperature. According to practical situation, the factory may exchange batteries for customers or makes customers renew electricity.
8.Do not use in line with instructions/batteries out of scope of “Three Guarantees” 1.Users modified.
2.Exceed “three guarantees” period.
3.End of service life.
4.Exceed “storage term”.		 1.Users modified and caused battery failure.
2.“Three Guarantees” period starts from sales date.
3.Storage period starts from sales date. 		According to “Three Guarantees” commitment, the factory carries out 3 years and 5 years “Three Guarantees” for 12V batteries and 2V batteries respectively.

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