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Repair ...Fixin' what's broke
Maintenance ....Fixin' what aint broke...yet.
When you discharge a Lead-Acid battery the lead oxide on the positive
plate and the lead on the negative plate combine with the sulfuric acid
in the electrolyte to produce lead oxide on both plates, water and free
electrons (a lot of them). When a battery is fully discharged the
positive and negative plates are chemically identical (lead sulfate)
and the battery can then, theoretically, be charged in with the
opposite polarity.
Lead, lead sulfate and lead oxide all have different densities so that
during the charge and discharge cycles the plates are expanding and
contracting slightly. One of the limiting factors in battery life is
mechanical fatigue of the plates. Over time they disintegrate and , in
wet cells, fall to the bottom and short the cell.
Batteries designed for starting engines have a low cell resistance and
a high peak current capacity. Batteries designed to provide standby
power are optimized for maximum power density and are referred to as
"Deep Cycle" type, as they are designed to be discharged until their
cell voltage falls to a fraction of the initial voltage.
A typical (in this case) battery is composed of cells. Each cell
produces a nominal 2.0 volts so several cells are connected in series
to produce the needed voltage. Because they are manufactured at the
same time, these cells are nearly identical in performance, which is a
good thing because if one cell fails the battery fails. A battery only
has the capacity of the weakest cell. Because both charging and
discharging produce heat and the cells are stacked side by side, the
middle cells run a little hotter than the cells on the end and
therefore end up having slightly different performance. This difference
is small and insignificant MOST of the time. The time it becomes
significant is when the battery is completely discharged. During a
complete discharge, one cell reaches exhaustion first but it is still
part of the circuit so the other cells are still trying to push
electrons through it. What happens when you push electrons through a
battery rather than it doing the pushing? It charges, but it charges in
the reverse polarity (remember the plates of a discharged battery are
chemically identical). This "cell reversal" is very damaging because a
large portion of the remaining charge in the stronger cells is dumped
in to to weakest cell. The mechanical stresses on a "reversed" cell are
very high due to the density changes mentioned above. To make matters
worse the internal cell resistance increases as the battery discharges
so the batteries ability to accept a charge current also decreases.
This is why the charging current on a completely dead battery starts
out low then climbs rapidly and then falls slowly as the battery
charges.
Battery life is frequently specified in charge discharge cycles and a
cycle is usually specified as a percentage of capacity (e.g. 80%).
Using only a portion of the capacity will extend the life and using ALL
the capacity will shorten the life. Running the battery all the way out
to cell reversal will GREATLY shorten the life. How much is that? I
can't say. But it would be a good idea to replace the badly abused
battery at the next annual or major service.
The energy capacity of a battery decays with time and use. If you wait
until you notice that your battery performance is marginal it will
likely be the time you need it most. It is better to replace on "time"
as a maintenance item than on "performance" as a repair item. Depending
on service, temperature swings, and flight hours, replacing your
battery every two to three years would be a good plan.
Regards
Brent Regan
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