User Manual

Batteries in a good or acceptable condition should be above 6.4 Volts (6 Volt
Battery); 8.5 Volts (8 Volt Battery); and, 12.7 Volts (12 Volt Battery) after
receiving a full charge and an 8 hour rest / cool down period.
If batteries in the pack are below 6.1 Volts (6 Volt Battery); 8.1 Volts (8 Volt
Battery); and, 12.2 Volts (12 Volt Battery) after receiving a full charge – the
pack has failed as a result of age, abuse or normal duty cycle demands.
Any battery within the pack that is 0.25 Volts lower than the highest battery
voltage (6 Volt Battery); 0.35 Volts lower than the highest battery voltage (8 Volt
Battery); 0.50 Volts lower than the highest battery voltage (12 Volt Battery) has
likely failed. Repeat a pattern of Charge – Discharge – Charge – Discharge (with
intermittent voltage inspections) to verify the failure condition.
Battery testing is most effective as a diagnostic resource when employed at
scheduled intervals. An effective testing program can also identify conditions that
affect battery performance in normal as well as abusive use conditions – situations
that may result in premature failure. Crown Battery utilizes several AGM battery
test procedures that can be performed to verify battery serviceability. These tests
do not determine the battery’s actual capacity – but they can indicate a need for
replacement or a more complete assessment of battery integrity.
Safety. First.
Battery Inspection Process
1. Visual Inspection
Check battery age or length of service if available. Inspect
battery for physical condition – looking for damage to the
terminals, container and cover. The following points cover many
of the conditions and typical errors in operation that can be
observed during a visual inspection:
Condition Root Cause
Fluid or Moisture
Present on
Battery Cover
Evidence of overcharging.
Bulging End Walls –
Slight Bulge
Normal condition for batteries with large
cell structures. More prevalent in high
temperature conditions.
Bulging End Walls –
Severe Bulge
Abnormal – indicates overcharging or
a blocked valve.
Inward / Concave
End Walls or Cover
Normal condition that does not compromise
product integrity. The condition is affected by a
combination of changing operating temperatures
and internal battery gas pressures – and typically
self-corrects with regular cycling / charging.
Terminal Meltdown
Evidence of a loose or incomplete cable
connection to the battery terminal.
2. Fully Charge Batteries
Connect the battery pack to its matched charger and fully
recharge the batteries. Allow the batteries to rest / cool for at
least 8 hours following termination of charge.
3. Open Circuit Voltage Test
Inspect open circuit voltage of each battery in the battery pack.
Review and record battery voltage conditions. Evaluate and compare
battery voltages with the following State of Charge voltage points:
100%
S.O.C.
75%
S.O.C.
50%
S.O.C.
25%
S.O.C.
0%
S.O.C.
6 Volt Battery 6.42 6.27 6.12 5.97 5.82
8 Volt Battery 8.56 8.36 8.16 7.96 7.76
12 Volt Battery 12.84 12.54 12.24 11.94 11.64
Where possible – avoid mixing new batteries in
applications with older batteries. New batteries should
be replaced in whole packs to ensure the best success
for equipment owners and operators. Contact Crown
Battery via email at [e-mail]
for additional instructions.
4. Discharge Test
Qualified battery and equipment technicians can utilize approved
battery discharge testing equipment to verify battery integrity.
Discharge testing should be performed by applying a 25, 56 or 75
ampere load condition to a fully charged battery pack.
After commencing the discharge test, record the number of battery
runtime minutes until the discharge is complete. Battery packs which
deliver discharge times of at least 50% of their rated RC Minutes
specification, batteries are good and acceptable for service.
Battery Analysis &
Troubleshooting
Battery Replacement
Best Practice
Battery packs which do not deliver discharge times of at least 50% of their
rated RC Minutes specification require individual battery inspections to verify
battery integrity. At the termination of testing – record the end-of-discharge
voltage for each battery in the pack.
Any battery within the pack that is 0.25 Volts lower than the highest battery
voltage (6 Volt Battery); 0.35 Volts lower than the highest battery voltage
(8 Volt Battery); 0.50 Volts lower than the highest battery voltage (12 Volt
Battery) has likely failed and should be replaced.
1. Visual Inspection
2. Fully Charge Batteries –
Followed by an 8-Hour Rest Period
3. Open Circuit Voltage Test
4. Battery Discharge Test