Battery charging

 Battery charging, function description

o Safety instructions
o Important information on batteries
o Connecting battery charger
o Battery analyser
o Charging phase
o Normal charging
o Rapid charging
o Electrolyte Filling

Battery charging, function description

Safety instructions

If a body part comes in contact with battery acid, wash thoroughly with soap and plenty of water.
If acid should get into your eye(s), rinse out immediately with water and contact a doctor. Eye rinsing
facilities should be available at the charging station.
When batteries are being charged, a mist of sulphuric acid is formed. This mist is corrosive and
dangerous to inhale. In addition to this an Oxy-hydrogen gas is emitted; this gas is explosive and can be
ignited by an open flame, heat glow or sparks.

Important information on batteries

● Battery service life depends upon how well the battery is maintained.
Regular maintenance prevents unnecessary breakdown;
● Keep the battery clean, dry and cold:
 Low temperatures results in low battery discharge. A battery stored at room temperature
must be charged more often;
● The vehicle's alternator can never charge the battery to 100%;
In good conditions, today's vehicles can charge to 90-95%. To achieve a full charge, the
battery must be charged with a higher voltage than normal;
● Full charging can only be accomplished with a battery charger, over a long period of time
(20-30 hours) and with a current limitation of 8-12% of the battery capacity in Ah;
● Full charging can only be accomplished with a battery charger, over a long period of time
(20-30 hours) and with a current limitation of 8-12% of the battery capacity in Ah:
At -20°C a battery can only take in 1/10 of the current of a battery stored/operated at
25°C. Poor charging combined with short driving distances is the most common cause of
battery problems during the winter period;
● Volvo battery analyser immediately tells you if the battery is in good condition, needs to
be recharged or should be replaced;
● The battery charger must have a voltage limiter:
If there is no voltage limiter, charging can damage the vehicle electronics and the battery
can overheat;
● The battery charger must have sufficient power, for supplying the batteries with 8-12% of
the their capacity (in Ah). 225 Ah battery requires 20 A charging;
● Batteries connected in series, must have same CCA value (Cold Cranking Amps):
The battery CCA value is shown on the label, but should also be verified with Volvo
battery analyser;
● For conventional batteries check the electrolyte level and top up with deionised water,
before charging starts;
● Never charge a battery with a bad-cell.

Connecting battery charger

Remove power from the vehicle by turning off the main switch or by disconnecting the battery negative
cable and perform the following procedures:
(1) Connect the positive cable (red).
(2) Connect the negative cable (black).
For conventional batteries loosen all cell-plugs and let them sit loosely in their holes.
(3) Plug in the charger and begin charging.

Note

The temperature of the battery must not exceed 50 °C during charging.

After 20–30 hours of normal charging the battery should have regained its capacity. If not,
the battery is probably worn out and should be replaced.
 Note

The battery state of charge should be checked with the Volvo battery analyser before
charging.
Note

If anti-sulphating unit is fitted, the anti-sulphating unit must be disconnected before

charging.
Battery needs recharging when voltage is below 12.54 V or density is below 1.25 g/cm³ (at +25 °C).
Batteries operating in tropical conditions needs recharging when acid density is below 1.21 g/cm³ or
voltage is below 12.30 V.

Battery analyser
 Note

Volvo battery analyser exist in two version.

Always test the battery with the Volvo battery analyser before and after charging. The analyser
measures the conductance in the battery, patented method which is fast and does not affect the capacity
of the battery.
The Volvo battery analyser is used to:

● Detect if a cell is bad or short-circuited;

● Measure the battery's ability to accept charge;
● Quickly and simply test the battery condition and capacity;
● Test the complete charging system quickly, reliably and if the alternator is operating
correctly;
● Test if two batteries are equivalent (have the same capacity) and can therefore be used
together.
For further information see Battery analyser 7200 user handbook or Battery analyser user handbook,
group 31.

Charging phase
When charging, the battery voltage rises rapidly to approximately 12.9 Volts, and then slowly up to 13.8 -
14.4 Volts as gas production begins. The charging current must be reduced when gas production
begins. This is why a battery charger with a voltage limiter should always be used. The charging
curve varies depending upon the charging current, battery condition etc.

Normal charging
Observe the following instructions when charging the batteries:

● Charge for a long period of time (20-30 hours) at a low current;

● The current should be 8-10% of the battery capacity, e.g.:
■ 140 Ah batteries should be with 10–14 A;
170 Ah batteries should be charged with 14–17 A;
225 Ah batteries should be charged with 18–23 A.
When the terminal voltage has reached 14.4 Volts, charge the battery for another 5 hours.

Rapid charging
Note

Always check battery state of charge with the Volvo battery analyser, before charging.
Note
 Rapid charging with high current is not recommended, should only be used when
absolutely necessary.
Rapid charging with high current result in an intense gas production, which results in the following:

● Service life is shortened (the active lead on the plates becomes damaged and destroyed);
● Capacity is reduced The battery never becomes fully charged;
● The battery never becomes fully charged;
● Increased risk for explosion (oxy-hydrogen gas).
Rapid charging is done with high current (50-100 A) for a short period of time.
When charging, check at least every 30 minutes:

● The temperature of the battery (max 50 °C);

The electrolyte level.
Electrolyte Filling
 Note

Check the battery appearance: Should not have damages on the cover.
Perform the electrolyte filling observing the following issues:

● The electrolyte temperature should not be higher than 35°C;

● Avoid spill or overflow when injecting, they cause damaged skin.
● Inject the electrolyte to each grid;
● Liquid level should be between the max and min lines.