Troubleshoot

Check Battery Status by Voltage

Reference the values below to check the current status of your battery

What if my battery is below the minimum voltage?

Once a 12V battery dips below 10V (5V for 6V battery), the battery is at risk of sustaining damage from a process called sulfasion. When a lead acid battery sits in an uncharged state, the internal plates are coated with sulfer, creating a very large internal resistance. The longer the battery remains uncharged, the greater the risk of permanent damage.  Any warranty is considered void if the voltage has dropped below the minimum.

Why is my system failing?

Follow these steps to help determine the cause of equipment or battery failure for 12V (6V) battery.

1

Test Voltage – Measuring at least 12.2V (6.1V)?

Measure the battery voltage outside of the system using a volt meter.  We want to begin our test with a relatively charged battery if we can.  We’re looking for a minimum of 12.2V for a nominal 12V battery (or 6.1V for a 6V battery).  

NO

Charge the Battery

Place on an external charger for at least one hour.  Remove battery from charge and allow to settle for about five minutes.  (If you do not have an external charger, execute Step 3 to charge the battery.)  Return to Step 1.

YES

Move on to Step 2

!

Battery Remains below 10V (5V)

If the battery is below 10V (5V) and maintains a low voltage after an overnight charge, the battery is most likely drained beyond a recognizable voltage for the charger to turn on.  Replace the battery and begin troubleshooting steps again.  The cause of failure still needs to be determined.

2

Install and Test – Measuring at least 12V (6.1V)?

Install the battery and connect it to the equipment. Measure the battery voltage while connected and powered on.  During this stage, we want to leave the equipment unplugged from wall power to run off of only battery power.  If the voltage stays above 12V (6V), the battery has sufficient capacity to operate the equipment.  

NO

Battery Needs Replaced

If the battery is unable to maintain a voltage over 12V (6V), the capacity has been severely reduced and needs replaced.  This can be due to normal wear and tear (high number of cycles), improper storage (placed on a shelf with no charge for a long period of time), or due to lack of charge (used in equipment without being recharged).  

YES

Move to Step 3

!

Before Replacing Battery…

Continue to Step 3 knowing the battery needs replacement. We may find our dead battery has been caused by a faulty charger. Replacement without further investigation, in this case, will cause another dead battery very quickly.

3

Charge Battery Using Equipment – Is voltage increasing?

Use the system charger to charge the battery.  In most cases, this means plug in the machine to wall power.  For some equipment, like excersize bikes, you may have to run the charger through mechanical operation.  The voltage should increase during the charge cycle.

NO

Insufficient or No Power Output

If the voltage does not increase over the charge cycle, the system charger is either putting out no power or is putting out less power than is being consumed by the equipment.  The equipment or charger will need replaced. A new battery installed in equipment with a faulty charger will cause battery failure within a few months. This type of failure is outside the control of the manufacturer and is not covered under the warranty.

YES

Operating Normally

Internal charger has sufficient output power and is supplying more power than is consumed by the equipment.  We can start to look to other causes of battery failure.

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Seeing strange results?

Contact us if you’re not sure what your results indicate.  You can also return the battery to us for testing if you’re not comfortable or don’t have a volt meter. CONTACT US

How long will my battery last?

More accurate than the amount of time a lead acid battery will last is the number of cycles it will last.  The deeper the discharge cycle, the fewer number of cycles a battery will supply.  For example, a typical general purpose battery will supply between 200-300 cycles at 100% depth of discharge (to 10V for a 12V battery).  The same battery will supply upwards of 1000 cycles at 20% depth of discharge, 80% remaining charge (12.6V for a 12V battery).