www.bannerbatteries.

com

TECHNICAL
GUIDE
2_GENERAL SECTION

CONTENTS.
Introduction .......................................................................................................... Page 5
Banner website ................................................................................................... Page 6
Technical principles .......................................................................................... Page 8
Battery use ...........................................................................................................Page 24
Energy household ...........................................................................................Page 50
Service ....................................................................................................................Page 60
Lexicon ...................................................................................................................Page 70
Sales region .........................................................................................................Page 74
4_GENERAL SECTION

Audi
BMW

Porsche Mercedes

VW
Škoda Bomag

Aston
Martin Dethleffs
Hymer

AIXAM Kässbohrer

Volvo KTM

Rammax Liebherr
Mitsubishi
INTRODUCTION
Banner is one of Europe’s largest battery manufacturers and produ-
ces and markets starter batteries that constantly meet the highest
demands of current vehicles, as well as traction-device-stationary
batteries, wheel weights and a tailor-made programme of acces-
sories.

Banner is an independent, family-owned company with a plant in

Linz/Austria, which produces quality certificated according to ISO
9001 and ISO/TS 16949. Banner also makes a valuable contribution
to environmental protection through battery collection, complete
recycling and a management system in line with ISO 14001.
6_GENERAL SECTION

THE POWER PAGE

ON THE WORLDWIDE WEB.
Detailed information concerning Banner and its products, current
news and offers are available on the Banner Power Page.

q Product Finder
Discover the ideal product for your application!

q Dealer Finder
Pinpoint the official sales partner in your vicinity!

q FAQs
Gather quick and efficient information
regarding battery advantages and uses.

www.bannerbatteries.com
8_TECHNICAL PRINCIPLES

WHAT IS A BATTERY?
A battery is a device consisting of several, identical, interconnected
galvanic cells, which is able to store chemical energy. Voltage is crea-
ted whenever two differing metals are found in an electrolyte so-
lution (galvanic cell). This voltage depends upon the type of metal
(electrochemical voltage series), the solution concentration and the
temperature. In the case of lead-acid batteries, the positive electrode
is made of lead oxide and the negative electrode of lead. Diluted
sulphuric acid is employed as electrolyte and provides a rated volta-
ge of 2 V per cell. Therefore, in a 12 V battery, six cells must be inter-
connected in series.

Dependent upon whether or not batteries can be recharged, a dif-

ferentiation is made between primary elements that can only be
discharged once and secondary elements, which can be recharged
several times during their service life.
A further differentiation is made with regard to the area of applica-
tion. Device batteries are used mainly for the supply of small items
of electrical equipment and traction batteries for electrical vehicles,
while among other applications, stationary batteries are employed
for the provision of an uninterrupted power supply.
As a rule, starter batteries (= SLI batteries – starting, lighting, igni-
tion) are used for the ignition of combustion engines. They supply
a large amount of energy for a short period and are able to initiate
several thousand starting procedures.

In addition, a considerable number of battery types, which for ex-

ample differ with regard to their mesh technology (alloys), as well
as vented and valve regulated batteries, are available on the market.

Although the principle of the lead battery is relatively old, it remains

in successful current use. The lead battery continues to offer the best
compromise between reliability, usability, robustness and price.
10_TECHNICAL PRINCIPLES

BATTERY DESIGN.
q A 12 V battery consists of six cells interconnected in series (rated
voltage of a lead-acid cell = 2 V), which are installed in a battery
casing divided by separating walls and connected in series by a
cell connector.

q Each cell consists of a plate block comprised of a positive and a

negative plate set.

q Separators keep the electrodes with differing polarity apart. In the

case of wet batteries, a polyethylene separator is used and in AGM
batteries, a highly absorbent glass mat separator, which binds in
the electrolyte.

q The electrodes are formed by a lead grid (expanded metal, Con-

Cast and book casting technology) and active mass. The individual
electrodes are linked to a both negative and positive plate set by
the connector.

q Diluted sulphuric acid serves as electrolyte (acid density of a fully

charged sealed battery: 1.28-0.01+0.02 kg/l).

q Differing pole diameters (the positive pole is thicker than the ne-
gative pole) prevent the false connection of the battery.
qBatteries are closed using a number of differing lid designs. In the
case of AGM batteries, apart from a reinforced casing, special
screws are employed that provide an airtight sealing.

Special screws
Backfire protection

Valve holder

Positive set

Plate set

Negative set

Negative plate

Mesh

Mat separator

Positive plate

Mesh
12_TECHNICAL PRINCIPLES

BATTERY FUNCTION.
Two electrodes, which are linked inside the cell by a solution (elect-
rolyte), are required for the conversion of chemical energy into elec-
trical energy (galvanic process). In a charged condition, the electrode
plates are comprised of lead and lead oxide. The positive electrode
consists of lead oxide and the negative electrode of lead. Diluted
sulphuric acid forms the electrolyte, which ensures the flow of ions
between the electrodes. The electrolyte can be liquid, gel-like or be
bound into a glass mat, as is the case in an AGM battery.

When the battery supplies power, the negative charged sulphate

ions (SO4 2-) from the sulphuric acid (H2SO4) are bound on the pla-
tes. Both plates are gradually turned into lead sulphate (PbSO4). The
uncharged lead atoms (Pb) of the lead plate are positively charged
twice (Pb 2+) and the previously fourfold positively charged lead ions
(Pb 4+) in the lead oxide plate are also positively charged twice.

The lead plate is electrochemically oxidized (von Pb auf Pb 2+), while

the lead oxide plate undergoes an electrochemical reduction (from
Pb 4+ to Pb 2+). In order to compensate for the charge gradient, elec-
trons flow from the lead plate to the lead oxide plate. The battery
supplies current.
 Acid density 1.28

Charged

Current output

Discharged

Water

Chem. Symbol key

Lead
Lead oxide
Charged Sulphuric acid
Lead sulphate
Water
Hydrogen
Oxygen
Sulphate
14_TECHNICAL PRINCIPLES

STATE OF CHARGE.

Conventional b

Acid density
Charged condition
25°C%[kg/l]
100 % Approx. 1.28
90 % Approx. 1.26
80 % Approx. 1.24
70 % Approx. 1.22
60 % Approx. 1.20
50 % Approx. 1.18
20 % Approx. 1.10
0 - 10 % Approx. 1.05

No vehicle installation

Installation in vehicle

Batteries with an open circuit voltage < 12.5

 AGM battery
battery (vented)
(valve regulated)
Open circuit voltage Open circuit voltage
[V] [V]
> 12.70 > 12.90
> 12.60 > 12.75
> 12.50 > 12.65
> 12.40 > 12.50
> 12.30 > 12.40
> 12.20 > 12.25
> 11.80 > 11.80
> 10.50 > 10.50

50 V are to be recharged immediately!

16_TECHNICAL PRINCIPLES

SELF-DISCHARGE.
After a certain time, even when the battery is not connected to
any consumers, it becomes electrically empty. This occurrence is
described as self-discharge and is caused by the chemical proces-
ses in the battery.

The extent of self-discharge depends upon the temperature, the

acid-mass ratio and the battery technology.

A change in the storage temperature of 10°C results in a doubling

of self-discharge (Arrhenius’ Law). Self-discharge has a special in-
fluence in the case of seasonally employed vehicles such as those
used in agriculture and the construction industry, motorcycles,
caravans and convertibles.

In order to prevent irreparable damage, all batteries must

be recharged from a voltage of 12.50 V.
Recharge limit
70 % charge status

50 % charge status
18_TECHNICAL PRINCIPLES

SERIES CONNECTION.
During series connection the voltages of the individual batteries
accumulate. In order to create a 24 V electrical supply system, two
batteries must be connected in series.

Please note:
q Both batteries must have the same type designation.
q Both batteries must be of roughly the same age.
q Both batteries must have the same charge status.
q The connecting lines must have sufficient dimensions and be as
short as possible.
q Always exchange both batteries!

Should the aforementioned recommendations not be followed, dif-

fering internal resistance of the individual batteries causes a corres-
ponding voltage distribution and thus an asymmetrical load during
the loading and discharge phase.

The charging equalizer provides two batteries connected in series

with a uniform charge status.
20_TECHNICAL PRINCIPLES

PARALLEL CONNECTION.
In a parallel connection, the individual capacities and the cold start
current of the individual batteries are accumulated.

Please note:
q Both batteries must have the same type designation.
q Both batteries must be of roughly the same age.
q Both batteries must have the same charge status.
q The connecting lines must have sufficient dimensions and be as
short as possible.
q Always exchange both batteries!

Should the aforementioned recommendations not be followed, dif-

fering internal resistance of the individual batteries causes a corres-
ponding voltage distribution and thus an asymmetrical load during
the loading and discharge phase. As a result, partly high equalizing
current flows between the batteries.

Where installation allows, the use of only one battery with a larger
capacity is to be recommended.
22_TECHNICAL PRINCIPLES

OUTPUT CAPACITY AND

ENERGY REQUIREMENT.

A battery has its maximum output capacity at a room temperature

of 25°C. The colder the temperature, the slower the chemical pro-
cesses in the battery and hence the lower its output capacity.

Engines also prefer warm temperatures, as the engine oil is very

fluid and friction is reduced. However, as the temperature falls the
energy required for starting increases massively. Consequently, the
highest starting power is required when the battery has a poor out-
put capacity.

Therefore, many batteries tend to fail in the cold period of

the year.
Battery output capacity

output

Energy requirement of the engine during starting

Engine energy requirement
24_BATTERY USE

WARNING!
Please obtain additional information regarding the secure handling
of lead batteries from the product datasheet concerning starter
battery safety on our homepage:
http://www.bannerbatterien.com/banner/files/safety datasheet_
ZVEI_D03.2013.pdf
Warnings and safety instructions for lead-acid batteries
Adhere to the information printed on the batteries, in the instructions
for use and the vehicle operating manual.
Wear eye protection.
Keep children away from acid and batteries.
Danger of explosions:
- A highly explosive oxyhydrogen gas mixture is created during battery charging.
Open flames, sparks, open lights and smoking are prohibited:
- Avoid sparks when handling cables and electrical devices! Avoid short circuits!
Danger of chemical burns:
- Battery acid can cause severe burns therefore.
- Wear gloves and eye protection!
- Do not tip the battery, as acid can escape from the degassing valves.
First aid:
- In the case of acid splashes in the eyes, immediately rinse out with clean
water for several minutes! Then consult a doctor without delay!
- Treat acid splashes on the skin or clothing with an acid neutralizer or soap
and rinse with large amounts of water.
- Should acid be swallowed, consult a doctor immediately!
Warning:
- Do not subject batteries to direct daylight.
- Discharged batteries can freeze; therefore use frost-free storage.
Disposal:
- Used batteries should be handed in at a collection point. The information
provided under Item 1 should be taken into account during transport.
Never dispose of batteries with household waste!
26_BATTERY USE

BATTERY TECHNOLOGIES.

AGM
The absorbent glass mat (AGM) battery is of recombination
design.

A glass mat separator absorbs the acid and leaves sufficient pores
free, in order to facilitate oxygen diffusion from the positive to the
negative plate. On the negative plate, the oxygen combines with
lead to form lead oxide. This lead oxide then reacts with the sulphuric
acid to create lead sulphate, whereby water results as a reaction pro-
duct. Charging then causes the lead sulphate to convert back into
metallic lead. As a consequence there is no water loss!

In view of the predominant cell overpressure, the battery casing is of

even more stable design and the lid is fitted with special overpres-
sure valves, which may never be opened. Moreover, compact instal-
lation presses the electrode plates so closely together that sludging
is reduced greatly, thus providing very high cyclical and vibration
resistance.
However, if owing to excessive charge voltages or extremely high
temperatures excessive gas is formed, recombination is no longer
complete. The pressure in the battery rises continually until the sa-
fety valves open.

Banner recommendation. For safety reasons, when installing the

battery indoors always use a degassing hose, which in an emergency
will conduct the gas outwards.

Negative electrode Positive electrode

Valve

Glass mat separator

soaked in acid
28_BATTERY USE

AGM

TECHNICAL DATA AND INFORMATION

q Valve-regulated lead acid battery (VRLA)
q Threefold cycle resistance as compared to standard starter batteries:
highest E4 classification pursuant to EN 50342-1
q Leak-proof owing to the electrolyte being bound in
(absorbent glass mat - AGM)
q Absolute maintenance-free due to recombination technology
q Highest V3 vibration resistance pursuant to EN 50342-1
q Highest start performance thanks to very low internal resistance
q Installation in a lateral position possible (max. 90° angle of inclination)
q Flexible use as a starter and electrical system battery
 AGM
TECHNO
LOGY

START STOP
ENERGIERÜCKGEWINNUNG
ENERGY RECUPERATION
30_BATTERY USE

EFB
The enhanced flooded battery (EFB) is an upgraded conven-
tional battery.

Special additives and the use of a polyester scrim lend the active
mass additional hold. As a result, the battery has improved cyclical
resistance and is extremely vibration resistant.

Banner recommendation. For safety reasons, when installing the

battery indoors always use a degassing hose, which in an emergency
will conduct the gas outwards.

TECHNICAL DATA AND INFOS

q Nonwoven layer on the separator and a special active mass recipe
q Twice the cycle life as compared to standard starter batteries.
E3 classification pursuant to EN 50342-1.
q Highest V3 vibration resistance pursuant to EN 50342-1
q Double-lid top for maximum leak protection and the highest
operational safety
q Absolute maintenance-free owing to modern calcium mesh
technology
 EFB
TECHNO
LOGY

START STOP
32_BATTERY USE

CONVENTIONAL LEAD-ACID BATTERY

Since its development over a century ago, the conventional lead-acid
battery has been continually further developed and is still in success-
ful use. It continues to offer the best compromise between reliability,
usability, robustness and price, as well as providing OEM quality for
retrofitting. The Power Bull, which was designed according to BMW’s
and VW’s first fitting standards, is Banner’s premium starter battery for
modern vehicles, as well as the first choice as a replacement battery.

TECHNICAL DATA AND INFOS

q Robust cycle behaviour; E2 pursuant to EN 50342-1
q Double Top – double leak protection: 100 % leak-proof
up to an inclination angle of max. 45°
q Absolute maintenance-free owing to modern calcium technology
q Optimized cold start values, maximum starting power
q Extensive coverage of the European and Asian vehicle fleets
q Vibration-resistant owing to the floor bonding of the electrodes and
robust cell connectors; V2 classification pursuant to EN 50342-1
q Improved backfire and ESD safety (against electrostatic discharge)
34_BATTERY USE

ENERGY BULL
With the Energy Bull, Banner offers a special battery for hobbies and leisu-
re. The characteristics of the Energy Bull make it robust and the ideal ener-
gy source for camping/caravans, boats and many other applications up
to signal systems and traction batteries for electrical motors. For example,
in combination with bag separators and a special mass composition, the
robust mesh structure ensures extreme cyclical resistance.

TECHNICAL DATA AND INFOS

q Extremely cycle-resistant and durable – three times the cyclical
resistance of a starter battery
q Maintenance-friendly – easy to open and MIN/MAX marking
on the transparent housing
q Backfire resistance – the backfire safeguards are integrated
into the surge protectors in the battery lid
q Low-maintenance – reduced water consumption and self-discharge
q Simple charging – charging with conventional chargers
q Vibration-resistant – floor bonded plate sets and bag separators
covered with a glass mat; V3 classification pursuant to EN 50342-1
q Optimized capacity – ideal for cyclical loads
q Environment- and user-friendly – delivered filled and charged
q Practical handles
Banner tip. For safety reasons, when installing the battery indoors
always use a degassing hose, which in an emergency will conduct the
gas outwards.
36_BATTERY USE

CALCULATING THE CAPACITY

REQUIREMENT.
How to calculate the correct capacity for the battery in your
electrical system: Assuming that you are looking for a battery for
an e-boat, in a 24 V electrical system a 600 W e-motor is employed. In
addition a radio, various navigational lights and a sonar device have
to be supplied with power (total of 50 W). Should you wish to have
five hours of independent power, the various values involved are
used in the following formula:

Watts : Volts = Amperes x Hours x Safety Factor = Total Capacity in Ah

Accordingly: 650 : 24 = 27 x 5 x 1.7 = 230 Ah (K20)

As a rule, a safety factor (for the prevention of deep discharges) of

70 % should be applied for wet batteries (30 % for recombination
batteries, i.e. AGM and gel). For the example above, we would re-
commend two Energy Bull 968 01 batteries (230 Ah respectively)
connected in series.

In addition, use our online capacity calculator:

http://www.bannerbatterien.com/banner/products/batteries/
energy_bull/calculator/index.php
38_BATTERY USE

GRID TECHNOLOGIES.

TYPE DESIGNATION ADVANTAGES

Minimum H2O consump

Ca alloy for positive and Minimum self-discharg
Ca / Ca
negative grid (+Ag + Sn) Absolute maintenance-
High cold start power

Antimony alloy for the Low H2O consumption

Hybrid positive grid, Ca alloy for Low self-discharge
the negative Very robust battery

Antimony alloy for the

Charge acceptance
Antimon positive and negative
Cycle resistance
grid
S WEAKNESSES APPLICATION
Maintenance-free
ption
Higher charging voltage batteries
ge
Shorter service life under AGM batteries
-free Running Bull AGM,
extreme cyclical loads Running Bull AGM, EFB,
EFB,
PowerPower
Bull Bull

Starter batteries, light

No absolutely maintenance- cycle batteries
free batteries possible Truck applications
Buffalo Bull,
Buffalo Bull,+ +
SHD
SHD

Water consumption Truck applications

Self-discharge Cyclical batteries
Maintenance requirement Energy Bull
Energy Bull
40_BATTERY USE

THE CORRECT CHOICE OF A BATTERY.

The following guidelines must be followed in order to select
the right replacement battery:

Note the technology of the original battery (upgrades are

permissible).
q If the original battery was an AGM, the replacement must also be
an AGM.
q Where EFB batteries were originally installed, basically EFB batte-
ries must be retrofitted. AGM batteries may also be used in order
to prolong battery life.
q Where conventional batteries were originally installed, EFB or AGM
batteries can be retrofitted.

Retrofit with the original dimensions.

q Where there is space for batteries with a height of 190 mm, these
should be retrofitted instead of batteries with a height of 175 mm.
Batteries with this extra 15 mm tend to have a greater acid volu-
me, which results in superior charge acceptance.
Retrofit with powerful batteries.
q Wherever possible, battery types with the biggest capacity (not
the maximum cold start performance) should be selected, or the
largest battery suitable for installation employed.
q Under no circumstances should a replacement battery be ins-
talled for reasons of price, when this has a far lower capacity than
that of the original.

Retrofitted energy consumers require a more powerful battery.

q Retrofitted energy consumers such as stationary heating, sound
systems, cool boxes, etc. mean that the output of the original
battery is insufficient and therefore battery life will be drastically
shortened.

Our Product Finder on the Banner homepage also provides

assistance!
http://www.bannerbatterien.com/banner/product/finder/index.php
42_BATTERY USE

BATTERY INSTALLATION
AND REMOVAL.
Always heed the safety warnings!

q Only install batteries with an open circuit voltage of >12.50 V

in a vehicle!
q Follow the vehicle instructions.
q Voltage interruptions can result in data loss. The Banner
Memory Saver provides assistance.
q Before fitting or removing the battery, switch off the engine
and all power consumers.
q Avoid short circuits due to tools.
q When removing the battery, first disconnect the negative (-)
terminal and then the positive (+) terminal.
q Prior to fitting the battery, clean the battery compartment.
q Ensure that the battery is secured tightly.
q Clean terminals and battery clips and lubricate slightly with
acid-free grease.
q When fitting the battery first connect the positive (+) terminal and
then the negative (-) terminal. Ensure that the clips are secured.
q Original parts and sleeves are to be put back in place.
44_BATTERY USE

STORAGE AND TRANSPORT.

Storage
q Only store fully charged batteries with short circuit protection.
q Batteries are to be kept in a dry, light-protected and cool
(frost-free) place.
q The open circuit voltage of the batteries is to be checked
regularly and from 12.50 V the batteries are to be recharged.
q If a battery is to be taken out of service in the winter months,
it should be removed from the vehicle.
q If the battery is left in the vehicle, the negative terminal
should be disconnected.
q As an alternative, a charge retention device can be used.

Transport
q In line with UN 2794, Banner declares all starter batteries as wet
and filled with acid!
q Filled batteries are to be transported and stored in an upright
position, otherwise acid spillages can occur.
q During transport batteries must be secured against tipping
and slippage.
q Short circuit protection is essential.
q Detailed information is available in our product datasheet
regarding starter battery safety:
http://www.bannerbatterien.com/banner/files/
safety data sheet_ZVEI_D03.2013.PDF
BATTERY MAINTENANCE.
Check on the correct connection of the battery cable.

q Loose battery cables result in increased transitory resistance,

which leads to incomplete charging and reduced cold
starting current.
q The battery may not be covered in dirt. Increased self-
discharge derives from permanent creepage current.
q Terminals must be kept clean and greased.
q Oxidized terminals also result in increased transitory resistance,
which leads to incomplete charging and reduced cold
starting current.
q Regular checks of the electrolyte level in wet batteries and if
necessary, top up with demineralized or distilled water to
the maximum acid mark, or 15 mm above the upper plate
edge. Never refill with acid. In the case of high water losses,
a specialist should check the governor voltage.
46_BATTERY USE

BATTERY CHARGING.
Always heed the safety warnings!
q Before charging batteries, check the electrolyte level and if ne-
cessary top up with de-ionized or distilled water to the maximum
acid level mark, or 15 mm above the upper edge of the plates at
a maximum.
q Banner recommends that standard flooded batteries be charged
outside the vehicle with 16 V for 24 hours.

Warning! Many chargers have a type of resuscitation mode for deep

discharged Ca/Ca batteries. However, these only maintain a charging
voltage of 16 V for a short period.

Running Bull AGM/BackUp:

Always recharge with a voltage-controlled charger (max. 14.8 V).
The use of a standard charger without voltage control destroys the
battery due to overloading and cause the electrolyte to escape.
Warning! Follow the vehicle manufacturer’s instructions when
disconnecting the terminals.

q Batteries may only be charged with direct current. Connect the

positive (+) battery terminal to the positive (+) terminal of the
charger, and the negative (-) battery terminal to the negative (-)
terminal of the charger.
q Do not switch on the charger until the battery has been connec-
ted. First switch off the charger when charging is completed.
q It is recommended that the charging current be equal to at least
one tenth of the capacity (e.g. 44 Ah: 10 = 4.4 A charging current).
q The temperature of the acid may not be higher than 55°C
during charging. If the temperature exceeds this level, the charging
process must be discontinued.
q Charging is finished when the current drops to 0 or stops falling,
or if the automatic charger switches off.
q Charging must be performed in a well-ventilated room.
q The battery screws may not be opened.
q Ensure that recharging amounts to 1.2 times the consumed capaci-
ty (e.g. Consumed capacity 30 Ah, recharge 36 Ah).

Warning! Highly explosive oxyhydrogen gas is formed during char-

ging! Fires, sparks, open flames and smoking are strictly prohibited!

Recharging batteries inside the vehicle.

As a rule, fully automatic chargers (max. charging voltage 14.8 V)
are well suited to the charging of batteries installed in the vehicle.
Should the charger have an automatic mode with > 15.9 V voltage,
the battery must be separated from the vehicle electrical system or
removed from the vehicle. Otherwise, in a worst-case scenario the
installed control devices can be destroyed due to overvoltage with
huge resultant damage. Please take careful note of the battery
charger type. Useful tips regarding charging in the vehicle are often
contained in the operating instructions of the vehicle manufacturer
or those of the charger producer.
48_BATTERY USE

ASSISTED STARTING.
q In view of the sensitive electronic components in the vehicle, as
a rule starting assistance should only be provided by means of a
Banner Booster.
q Starting assistance from vehicle to vehicle can lead to voltage
peaks during disconnection, which can damage or even destroy
vehicle electronic systems.
q Therefore, it is essential that the following procedure be strictly
observed when using starter cables!
q Standardized starter cables (e.g. in accordance with DIN 72 553)
should always be used for giving starting assistance.
q Observe the instructions for use of the starter cables.
q Only connect batteries with the same nominal voltage.
q When connecting the terminals, switch off both vehicle engines!
First connect the two positive terminals (1) with (2). Then connect
the negative terminal of the assisting vehicle (3) with (4), the blank
metallic point on the vehicle needing assistance, away from the
battery. (Observe the instructions of the vehicle manufacturer.)
q Now start the vehicle needing assistance for a maximum of 15
seconds. Do not start the assisting vehicle.
q When disconnecting the terminals, remove the cables in the
reverse sequence to the above.
Battery Battery
of the of the
assisting vehicle
vehicle needing
assistance
50_ENERGY HOUSEHOLD

INFLUENCES ON THE ENERGY HOUSEHOLD.

Apart from battery capacity, the power requirement of the electricity
consumers, alternator performance and respective driving profile all
have a major influence on the energy household of a vehicle. Overall
consumption and individual driving conditions are decisive in this
regard.

Favourable load conditions

The alternator produces more power than is needed by the electri-
city consumers. The surplus current is used to charge the battery.

Alternator

Battery is charged

Consumers
Unfavourable load conditions
The current from the alternator is insufficient to supply all the elec-
tricity consumers, e.g. fog lights, seat heating, wing mirrors and rear
window heating. Accordingly, in order that all the consumers can be
operated, additional energy is taken from the battery.

Alternator

Battery is discharged

Consumers
52_ENERGY HOUSEHOLD

INCREASED OUTPUT REQUIREMENTS.

The demands made on starter batteries also increase significantly

with every new vehicle generation. Indeed, the progressive enlarge-
ment of electrical systems presents starter batteries with a growing
challenge. In modern cars the energy needs of electronic consumers
exceeds the output capacity of the alternator with the result that the
battery is additionally burdened. Today, an electrical requirement of
over 5,000 W and more than 100 e-motors is far from unusual. This
frequently leads to a negative energy balance at the expense of the
starter battery and as a final consequence, battery failure due to
deep discharge.

Banner tip. Completion of a battery check by a specialist at least

twice yearly and external, equalizing charging where necessary.
 54_ENERGY HOUSEHOLD

Stationary heating 800 W

4-channel sound system, 200 W
and level
Radio with CD player 60 W
Air-conditioning 100 W
Engine timing / ignition 20 W
Heated front window 1,000 W
Fuel injection 100 W
Interior blowers 150 W
Front windscreen wipers 80 W
Radiator fan 500 W
Front headlights 130 W
Headlight washing system 50 W
Fog headlights 100 W
ESP / ABS 100 W
Steering wheel heating 50 W
Mobile navigation device 10 W
 .
er tip
Bann mend th t
e
com mos
We re ion of the s the
llat hu
insta r ful and t ossible!
e
pow battery p itional
st d
large vides ad es.
pro rv
This tput rese
o u

IT’S HARD TO BELIEVE WHAT YOUR

Banner BATTERY POWERS!

50 W Rear windscreen wiper

40 W Rear lights
40 W Indicators
200 W Rear window heating
60 W Seat heating
40 W Rear fog lights
30 W Heated wing mirrors
100 W Electric windows
2W iPod
40 W Heated washing jets
60 W Fuel pump
180 W Engine management
120 W Powered steering pump
200 W Oil pump
250 W Water pump

All the values listed above are averages.

56_ENERGY HOUSEHOLD

IRREGULAR DRIVING PATTERNS.

Owing to the continuing trend towards mobilization, second and
third cars are often standard in our households. However, these cars
are often driven only irregularly and in combination with stop and go
traffic, and occasionally short distances, as well as a large number of
cold starts (vehicles not garaged), their batteries often demonstrate
a negative charge balance. Such repeated undercharging may result
in battery failure due to deep discharge.

Banner tip. In the case of extremely short drives (complete/request)

external, equalizing charging at regular intervals.

Banner tip. In the case of seasonally used vehicles, employ chargers

with a charge retention function.
CLOSED CIRCUIT CURRENT.
Closed circuit current is the power that is taken from the battery
when the engine is switched off.

The causes of closed circuit current are control devices or electrical

consumers, which in spite of apparent inactivity have to constantly
react to external influences, e.g. remote radio operation, anti-theft
devices and in-board computers. High closed circuit current derived
from the run-up of control devices, e.g. for remote radio operations,
or owing to a defect in the electrical system, can result in the batte-
ry losing an increased amount of energy and failure after a longer
standstill period. In busy traffic areas (airports, multi-storey car parks),
the use of control devices causes increased closed circuit current
owing to the utilization of similar frequencies by all the vehicles.

Therefore, a separate mode is employed for the transport of new ve-

hicles. You can partly learn how to put the vehicle into this mode
yourself using your vehicle’s operating manual. In other words, a look
at the instructions can save unpleasant surprises.
58_ENERGY HOUSEHOLD

START/STOP SYSTEMS.
Start/stop systems have been developed to reduce markedly vehicle
CO2 emissions and fuel consumption. The basic idea is that the engi-
ne will be turned off in those phases when it is not required.

Apart from energy management and a sensor that measures the sta-
te of charge (SOC), health (SOH), function (SOF) and temperature of
the battery, the realization of a start/stop system demands special
batteries. AGM batteries are needed for start/stop systems with recu-
peration and EFB batteries for simpler start/stop systems.

Up to 200 shutdown criteria must be fulfilled for functionality. The

energy management communicates with the battery sensor and the
engine control unit and either switches off or reactivates individual
consumers and the engine as required. In addition, the idling speed
can be increased.

In the medium-term, 70 per cent of all new vehicles will be fitted

with start/stop systems.
 Open circuit power management, charging
Shutdown of individual consumers
Energy management system

Start/stop battery Battery sensor

management

Shutdown criteria
Cooling water temperature Engine control unit including
Gear lever position start/stop controller
Catalytic converter temperature
Vehicle speed Automatic
Driver’s door/engine hood shutdown/starting
Parking assistant Increased idling speed
Power requirement/consumers
External temperature
...
60_SERVICE

POSSIBLE BATTERY PROBLEMS.

UNDERCHARGING
Changed driving patterns (more short distances) and the resultant
increase in the electrical energy requirement may lead to the incom-
plete charging of the battery. It is frequently the case that the alter-
nator is unable to charge the battery to more than 80 per cent of its
capacity. Consequently, parts of the active mass are rendered inacti-
ve (sulphating) thus reducing the output and capacity of the battery.

OVERCHARGING
If the battery is already fully charged and nonetheless receives ad-
ditional energy, this leads to additional gassing and higher water
consumption. The battery continues to produce gas until either the
charger is switched off or no water is left. Increasing heat results in
the acceleration of the chemical processes in the battery and the
gas voltage drops. If the charging voltage is not adjusted to match
the change in temperature, the battery will be overcharged, which
will create the danger of mesh corrosion and severe battery ageing.
For example, in the case of an increase in battery temperature
of 10°C, both the reaction speed and mesh corrosion double.
Strong gassing also causes a considerable increase in the danger of
an explosion. Moreover, sealed gel and AGM batteries can be da-
maged by just one overcharge. This is especially problematic, as in
these batteries the electrolyte (acid) is bound in and topping up is
not possible.

BATTERY DEEP DISCHARGE - SULPHATING

Battery discharge results in lead sulphate. If the battery is not imme-
diately charged, or is incompletely charged, the lead sulphate crys-
tals assume a coarser structure and grow, thus reducing the porosity
of the lead surface. These crystals can only be converted back with
difficulty if at all. Therefore, depending on battery status and design,
within just a few days this can lead to the battery being unable to ac-
cept any current and becoming useless. Moreover, even if the batte-
ry is charged immediately and appears to be fully operative, as a rule,
damage remains with a negative effect on service life. Furthermore,
an increasing number of electronic components are being installed
in vehicles, which require electrical power even when the engine is
switched off. Such “hidden” consumers include alarm systems and
radio clocks (closed circuit current).
62_SERVICE

POSSIBLE BATTERY PROBLEMS.

STORAGE WITH AN INSUFFICIENT STATE OF CHARGE
The storage of batteries in a partly charged condition contributes
to premature ageing. In particular, this problem occurs frequently in
the case of leisure applications, e.g. with motorcycles, veteran cars
and boats, which are subject to extended standstills. As soon as the
charging status falls below 12.5 V, the ageing process and battery
sulphating accelerate rapidly.

STRONG CYCLIZATION
This emanates from numerous deep discharge and charging cycles.
Under normal circumstances, such loads do not generally occur un-
less the starter battery is used for other purposes, e.g. in taxis, for
the operation of truck loading platforms, as a traction battery (there
are special batteries for these applications), or as an electrical system
battery in boats and caravans.

UNDERDIMENSIONING OF THE BATTERY

This derives from insufficient battery capacity and leads to increased
cyclization and battery damage. It can also be caused by the exces-
sive power consumption created by retrofitted devices (e.g. sound
systems, stationary heating, cool boxes).
64_SERVICE

BATTERY TESTING.

CONTROL BATTERY USE

q Correct battery for the application
q Driving profile

VISUAL CHECK
q Damage, tightness
q Check the tightness of the battery cables
q Battery clean and dry (creepage current, increased transient
resistance)
q Detached labels and increased water consumption indicate
overcharging and/or high temperatures.

CHECK THE OPEN CIRCUIT VOLTAGE (OCV)

q Measure six hours after battery charging/discharge.
q Fully charged wet battery: OCV >12.70 V
q Fully charged AGM battery: OCV >12.90 V
MEASURE ACID DENSITY
q Acid density uniformly low > battery discharged
q Acid density in a cell markedly lower > short circuit
q Acid coloured brown> sludging due to strong cyclization
q Acid density does not correspond with the OCV > acid
stratification (acid density +0.84 =OCV/cell), e.g. acid density 1.20;
OCV 12.67 V: 1.20+0.84=2.04 V/cell > x 6 cells = 12.24 V > acid
stratification!
q Acid density uniformly high (~1.28 kg/l) –> battery in order

QUICK TESTING DEVICE

q Only limited validity. No assessment of service life and capacity
possible.
q Design (mass, separator, etc.), temperature and charging status
have a major influence on the test result.

BATTERY CHARGING

RENEWED CHECK ON THE ACID DENSITY AND CONTROL

WITH THE QUICK TESTING DEVICE

COMPLETE LOAD TEST

66_SERVICE

WARRANTY AND GUARANTEE.

q 8. Warranty and acceptance of responsibility for defects

q 8.1 Subject to the fulfilment of the agreed conditions of payment,

the seller is obliged to repair any design, material or production
defects with a negative effect upon functionality that may exist at
the date of hand-over in accordance with the stipulations of the
following terms. No warranty claims can be made of the basis of
information contained in catalogues, brochures, advertising
materials, written or verbal statements, which have not been
accepted into the contract.

q 8.2 The warranty period lasts 12 months, sunless special war-

ranty periods have been agreed for individual delivery items. This
also applies to supplies and services, attached to a building or real
property. The warranty period commences with the risk transfer in
accordance with Item 6.

q 8.3 A prerequisite for warranty claims is that the purchaser has im-
mediately made the defect known in writing. The purchaser has to
immediately prove the existence of a defect and provide the seller
with available information and data. In the case of a defect subject to
warranty in accordance in Item 8.1, the seller can either choose to re-
pair the defective article at the place of performance, have it returned
for the purpose of repair, or provide an appropriate price reduction.
q 8.4 All ancillary costs relating to the repair of the defect (e.g. as-
sembly, disassembly, transport, disposal, travel time) are to be
borne by the purchaser. For warranty work at the company of the
purchaser, the required staff, lifting gear, scaffolding and inciden-
tals are to be supplied free of charge. Replaced parts will become
the property of the seller.

q 8.5 Should the seller manufacture an item on the basis of de-

sign information, drawings, models or other specifications of the
purchaser, then the warranty of the seller only extends to comple-
tion according to the stipulated conditions.

q 8.6 Excluded from the warranty are defects originating from ar-
rangement and installation not carried out by the seller, insuf-
ficient setting-up, a failure to adhere to the installation require-
ments and conditions for use, overloading of the components
beyond the performance levels stated by the seller, negligent or
incorrect handling and the use of unsuitable supplies. This also
applies to defects, which can be traced to materials delivered by
the purchaser. In addition, the seller does not provide a warranty
for damage caused by third parties, atmospheric discharges, over-
loads and chemicals. The warranty does not extend to the repla-
cement of components subject to natural wear and tear. In the
case of the purchase of second-hand goods, the seller does not
provide a warranty.
68_SERVICE

q 8.7 The warranty is immediately null and void should changes or

repair work be carried out on supplied goods by the purchaser, or
by a third party expressly authorised by the purchaser without the
written approval of the seller.

q 8.8 Claims pursuant to §933b ABGB lapse with the expiry of the
period contained in Item 8.2.

q 8.9 The conditions 8.1 to 8.8 also apply to each case of defects
arising for other legal reasons.

PLEASE SEE THE GENERAL TERMS OF BUSINESS.

VERY GOOD
(1,4)
for the Banner
Power Bull P72 09
in the starter battery test
Edition 12/2012
70_LEXICON

IMPORTANT TERMS.
AGM
These batteries containing nonwovens bear the designation absor-
bent glass mat (AGM) or valve regulated lead acid (VRLA). Above all,
they are used in start/stop systems with recuperation and are cha-
racterized by the highest levels of cyclical and vibration resistance,
as well as very high cold start current. In addition, these batteries
are absolutely leak-proof as the electrolyte is bound in. The safety
valves may never be opened and special care must be taken when
charging these batteries. The charge voltage may not exceed 14.8 V.

EFB
The enhanced flooded battery is a further development of the con-
ventional wet battery. As opposed to the latter, the battery has im-
proved cyclical and vibration resistance owing to a separator with a
non-woven layer and a special mass recipe. It is used for less complex
start/stop systems.

Electrolyte
The ion conductor, which connects electrodes. Diluted sulphuric
acid is employed in lead-acid batteries.
EN 50342-1
This standard applies to lead-acid batteries with a rated voltage of
12 V, which are used primarily for the ignition of combustion engines,
lighting and the additional equipment contained in vehicles with
combustion engines.

Cranking performance
Cold cranking test current is a parameter for the starting capacity of
batteries in cold temperatures. In line with the EN50342-1 standard,
this test is completed at -18°C.

Capacity
The electricity output volume (Ah) constitutes battery capacity. The
rated capacity of starter batteries always relates to a 20-hour di-
scharge. The available capacity is dependent upon the strength of
the discharge current, temperature and battery age. Pursuant to the
EN 50342-1 standard, at a temperature of 25 +/- 2°C a new battery
must be able to provide discharge current of I = K202/20 h without
the voltage falling below 10.5 V.
72_LEXICON

IMPORTANT TERMS.
Recuperation
Braking energy recovery. The coasting energy derived from braking
is converted into electrical energy by the generator and stored in
the battery.

OCV
Open circuit voltage is the off-load voltage at the battery terminals
following the attainment of a steady-state value (min. 6 hours).

Self-discharge
Off-load discharge of the battery due to chemical processes in the
battery. Self-discharge is highly dependent upon temperature,
design and technology.

Separator
Ion-permeable material separates the positive and negative plates.
Polyethylene is used in wet batteries, glass mat in AGM versions.
SOC
State of charge: battery charge status.

SOF
State of function: functional status of the battery.

SOH
State of health: health status of the battery.

Deep discharge
Discharge of the battery to a very low depth (> 50 %).
www.bannerbatteries.com

OUR SALES REGION.

Raum für persönliche Notizen:
Austria
Banner GmbH, Banner Straße 1, A-4021 Linz
Tel.: +43/(0)732/38 88-0, Fax: +43/(0)732/38 88-21399
E-Mail: [email protected]

Bulgaria
Banner Baterii Bulgaria EOOD / Баннер Батерии Б-я ЕООД, Ul. Ljublana 46, J&L Center, 1. Stock /
Ул. Любляна 46, J&L Center, ет. 1., BG-1618 Sofia / София, Tel.: / Тел. +359/2/889 01 20,
Fax: / Факс: +359/2/889 01 21, E-Mail: [email protected]

Czech Republic
Banner Baterie ČR, s.r.o., Uhříněves, Přátelství 1011, CZ-10400 Praha 10
Tel.: +420/267 090-510, Fax: +420/267 090-522
E-Mail: [email protected]

Denmark
Banner Batterier Danmark ApS, Silovej 14, Solrød, DK-2690 Karlslunde
Tel.: +45/70 20 60 61, Fax: +45/70 20 60 69, E-Mail: [email protected]

France
Banner France SAS, Zone Industrielle No. 2, 5, Rue Vauban, F-68170 Rixheim
Tel.: +33/(0)3 89/44 28 38, Fax: +33/(0)3 89/54 13 28
E-Mail: [email protected]

Germany
Banner Batterien Deutschland GmbH, Kesselbodenstraße 3, D-85391 Allershausen (München)
Tel.: +49/(0)6441/30 73-23000, Fax: +49/(0)6441/30 73-23099
E-Mail: [email protected]

Hungary
Banner Batterien Hungária Kft, Ipari park, Jedlik Ányos u. 6, H-2330 Dunaharaszti
Tel.: +36/24/49 18 91, Fax: +36/24/49 18 92
E-Mail: [email protected]

Banner products are sold in more than 40 European,

African and Asian states via direct importers.
Netherlands
Banner Benelux B.V., Laan van Diepenvoorden 3, NL-5582 LA Waarle
Tel.: +43/(0)732/38 88-21512, Fax: +43/(0)732/38 88-21599
E-Mail: [email protected]

Poland
Banner Polska Sp. z o.o., ul. Gliwicka 234, PL-40861 Katowice
Tel.: +48/(0)32/203 72 45, Fax: +48/(0)32/203 72 46
E-Mail: [email protected]

Romania
Banner Baterii Romania s.r.l., B-dul Biruinţei nr. 67, RO-077145 Pantelimon, jud. llfov
Tel.: +4/021/3000 627, +4/021/310 11 49, Fax: +4/021/3000 637
E-Mail: [email protected]

Russia
OOO “Banner Batterien” / ООО «Баннер Баттериен», Krasnogorskij rajon, Promzona-37,
pos.Archangelskoe / Промзона-37, пос.Архангельское, Красногорский район
RUS-143420 Moskovskaja Oblast / Московская область
Tel.: / Телефон: +7/(499)504 98 69, Fax: / Факс: +7/(499)504 98 69
E-Mail: [email protected]

Slovakia
Banner Baterie SR, s.r.o., Za Stanicou 1, Nr. 1537, SK-83104 Bratislava 3
Tel.: +421/(0)2/43 63 43 44, Fax: +421/(0)2/43 42 18 74
E-Mail: [email protected]

Switzerland
Banner Batterien Schweiz AG, Banner Straße 1, CH-5746 Walterswil
Tel.: 0840 Banner (226637), Gratisfax: 0800 Banner (226637)
E-Mail: [email protected]

Turkey
Banner Akü San. ve Tic. Ltd. Şti., Beylikdüzü Mermerciler Sanayi Sit., 7. Cad. No:4
(Hellmann Logistik binası), TR-34520 Beylikdüzü - İstanbul
Tel.: +90/212/877 85 10, Fax: +90/212/879 29 72
E-Mail: [email protected]

United Kingdom
Banner Batteries (GB) Ltd., Units 5-8 Canal View Business Park,
Wheelhouse Road, Rugeley, UK-WS15 1UY Staffordshire
Tel.: +44/(0)1889/57 11 00, Fax: +44/(0)1889/57 73 42
E-Mail: [email protected]
www.bannerbatteries.com

Banner GmbH, A-4021 Linz, Banner Strasse 1

Tel. +43/ (0)732/ 38 88-0,
Fax Sales +43/ (0)732/ 38 88-21699
E-mail: [email protected]