User Manual

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• Battery(s) temperatures are very high.
• If at or near 51˚C (125˚F) shut off charge and allow batteries to cool.
• If a single battery or cell in a string is hot, this may indicate a cell failure or
short. Verify specific gravity for all cells and take voltage readings from each
battery and perform a load test to identity any cell failures and verify proper
cell operation.
• Battery cases are bulging on the sides.
• If case bulging is a concern upon receipt of new product, please notify your
Distributor and/or forward clear photos via a Technical Support Ticket or email
to [e-mail] for review.
• Due to the weight of electrolyte, some case bulging is normal. New battery
cases will “relax” after filling. Verify that electrolyte levels have not dropped
below the top of the plates before attempting to charge and top up with distilled
water as necessary.
• In the case of excessive bulging - your batteries may have been exposed to
temperatures of over 51°C (125°F). This high temperature has caused the
plates/chassis to swell and expand. There is no fix for this and eventually
the batteries will fail prematurely and require replacement.
• Your batteries may have frozen due to excessive cold temperatures. A fully
charged battery (specific gravity of 1.265) may freeze at -70°C (-94°F) or
more. A battery at 50% SOC may freeze at -20ºC (-4ºF).
• Battery Terminal has melted.
• This is most common with loose connections, causing a highly resistant
connection. This resistance has caused heat buildup and melted the
terminal connection.
• This can be caused by:
– Loose connections
– Over-tightened connections
– Improper sized cables (too small)
– Corroded connections
– Improper use of washers/lock washers
– Too many connections on the same terminal
• Battery case has split or cracked originating from the sides.
• The battery may have frozen in the past, which has weakened
the case structure.