
Replacing batteries in your cleaning equipment can be quite expensive. However, if you maintain those batteries right, you can save a big share of your allocated budget. This month, we’re going to tap into the details of cleaning machine batteries and how to maintain them.
Understanding batteries
Two types of lead acid battery constructions are common in cleaning machines.
Flooded cell, also known as “wet batteries”.
These are low in cost and need to be maintained by monitoring and filling the battery cells with distilled water. Although the battery cost is less, the maintenance cost is still there. These batteries have removable vent caps for adding distilled water.
AGM or Absorbent Glass Mat Batteries.
These batteries are maintenance free. These batteries are sealed, so the cells don’t need to be filled with distilled water every now and then. These are accompanied by cords that just need to be plugged in when the machine is not in use. These batteries cost more than the wet batteries but save the cost of maintenance.
Lead-Acid batteries life in a cleaning machine
The life of a battery depends on how well it was maintained and how much runtime you need when cleaning. If the batteries are well maintained and charged regularly, you can expect about 500 discharge charge cycles from a battery pack. For typical applications, that’s about 18 months of useful life.
Factors that reduce the battery pack’s useful life
Simply stating, anything that causes “sulfation” of the battery plates will reduce the it’s capacity. The more sulfation that occurs in a battery, the less capacity the battery has to power your cleaning machines. However, the damage caused by sulfation to your batteries can be avoided with a few precautions:
Over-discharging the batteries
Over-discharged batteries can lead to sulfate crystals formation. However, most of the modern cleaning equipment is designed with a low-voltage shut off. This prevents the machines from discharging too much.
Over-charging the batteries
Over-charging is equally bad for the batteries. Most cleaning equipment is designed to prevent overcharging. Smart chargers are programmed to prevent overcharging. You just have to ensure that you’re using the charger that came with the machine.
Long-term storage of batteries
All batteries self-discharge as they sit idle and when the battery voltage drops too low, sulfation happens. This is where you can make a difference. Most newer CEC smart battery chargers will switch over to a battery maintenance mode when the batteries are fully charged. This maintenance mode keeps your batteries fully charged, as long as the charger is plugged in. Need to store your machines for a few months? No problem. Just make sure the charger is plugged in and, if you have flooded cell batteries, make sure you have the right amount of electrolyte in the battery. (Instructions for topping off flooded batteries are below).
Too little electrolyte, flooded batteries only
If the battery plates are exposed to air, sulfation occurs very quickly. Always monitor flooded batteries to prevent plate exposure.
How to maintain a battery pack
Review the operation manual
Read the operation manual that came with your cleaning equipment before you use it. Each machine is designed in a different way and the maintenance is different according to its build and design.
Every 4 discharge cycles
Check the electrolyte level (flooded batteries only) when the battery is fully charged. Each cell is independent so you will have to check each and every one. Ideally, there should be about ¼ of an inch between the electrolyte level and the bottom of the battery fill well. However, do ensure that you don’t overfill the batteries with distilled water. When the battery is charged, the electrolyte will expand. If the batteries are too full, battery acid will spill out of the vent.
Once a month
Inspect the battery cables. Check for any damage and immediately replace the battery cables if you see cracks in the insulation.
Once a month
Check for corrosion and clean the battery terminals thoroughly with a brass brush. Removing corrosion helps maintain conductivity and prevents overheating.
Once a month
Check the battery terminal hardware and make sure it is tight.
Once a month
Equalize the charge on the battery pack. This helps reduce sulfation.
How to correctly charge lead-acid batteries
After you are done using your cleaning machine, charge the battery back.
- If you have flooded batteries, check and make sure the plates inside the battery are covered. Never charge a battery with any of the plates exposed to air and do not overfill discharged batteries.
- Put the machine in a well-ventilated room. Batteries emit hydrogen when they are charged, which can be flammable.
- Plug in the original battery charger. Be sure to use the charger that came with the machine.
- Wait for the charger to finish. Fully depleted batteries can take up to 16 hours to charge back to 100%. Undercharging your battery pack is a very common way to cause it to wear out prematurely.
Tips for setting up your own battery maintenance program
- Keep records! Keep track of the date the batteries were put into service and each maintenance check and action.
- Make yourself a battery maintenance tool kit. Put all your safety equipment, tools, and distilled water in a designated place. Set yourself up for success by planning ahead.
- If you have flooded batteries, consider installing a battery filling system. A battery filling system replaces the battery vent caps with a series of tubes and fittings. You can fill your battery pack to exactly the right amount using a single remote fill point. It’s a real time-saver and helps cut down on overfilling mistakes.