Maintenance of lead-acid batteries: Why Water Refilling Is Essential

Lead-acid batteries are still indispensable in many industrial sectors, especially in forklifts and similar equipment. One of the key aspects of their maintenance is regular water refilling, which is crucial for maintaining proper electrolyte levels.

Without regular maintenance, battery plates can dry out, leading to:

• •      - overheating,
  •      - reduced efficiency,
  •      - permanent battery damage.

Risks when refilling water

Working with lead-acid batteries involves certain risks, as these batteries contain corrosive acids that can cause serious injury if they come into contact with the skin or eyes. An additional danger is water overflow, which can result in dangerous mixing of water and electrolyte and potential battery damage.

How to improve safety when refilling water

Using appropriate safety equipment is essential. We recommend:

•      - protective goggles and acid-resistant gloves to prevent acid contact with skin and eyes,
•      - protective apron for added protection against potential spills,
•      - battery filling gun with an automatic shut-off system to prevent overfilling,
•      - visual flow indicator or propeller-style flow indicator for immediate visual control,
•      - pressure regulator to control water flow and prevent high-pressure damage,
•      - filter to ensure clean water without particles that could harm the battery.

Make your work easier with the right equipment

For larger systems, we recommend mobile water filling solutions such as:

•      - water filling carts for fast and efficient filling without physical strain,
•      - wall-mounted holders for larger containers for gravity flow without manual pumping.

Always have first aid ready

In case of accidents, quick response is crucial. We recommend always having:

•      - eye wash station or kit,
•      - fire blanket,
•      - fire extinguisher specifically rated for lead-acid battery fires.

The importance of water refilling in lead-acid batteries

Regular water refilling is key to maintaining these batteries. The electrolyte evaporates over time and must be replenished to ensure:

•      - optimal battery performance,
•      - extended battery lifespan,
•      - greater operational reliability.

Why not use tap water?

Tap water contains minerals, chlorine, and impurities that cause:

•      - build-up of deposits,
•      - corrosion of battery plates,
•      - reduced battery capacity,
•      - more frequent breakdowns.

What kind of water is suitable?

• Distilled water: produced through distillation (evaporation and condensation), removes all minerals, microorganisms, and impurities.
• Deionized water: produced by ion exchange, removes most minerals and ions, though may contain trace organic substances.

Both types are suitable for battery refilling as they prevent sediment buildup, extend battery life, and ensure stable performance.

Consequences of improper maintenance

Irregular or improper water refilling can lead to:

•      - dried-out battery plates,
•      - excessive heating,
•      - reduced capacity and efficiency,
•      - permanent damage requiring costly battery replacement.

By consistently using distilled or deionized water and following correct maintenance practices, you will keep your batteries in optimal condition and reduce the risk of unnecessary failures.