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BCI Battery Technical Manual BCIS-02 REV FEB02 Issued Current Revision: 1992-03 2002-02 RECOMMENDED TEST PROCEDURES FOR BATTERY MATERIALS 3.1 3.2 4.1 4.2 4.2.1 4.2.2 4.2.3 4.2.4 4.2.5 4.2.6 4.2.7 4.2.8 4.3 4.3.1 4.3.2 4.3.3 4.3.4 4.3.5 5.1 5.1.1 5.1.2 5.2 5.2.1 5.2.2 5.2.3 5.2.4 5.3 5.4 5.5 5.5.1 5.5.2 5.5.3 TABLE OF CONTENTS Material Requirements Standard Specifications for Pig Lead Hard Rubber Rubber Containers Rubber Covers Plastic Raw Material Resin Plastic Containers Acid Resistance Tests Impact Resistance 11 Bulge Test 13 Electrical Breakdown` 13 Adhesion 14 Tensile Pull Test for Side Terminals 14 Torque Test for Side Terminals 16 Leakage Test for Side Terminals 17 Plastic Covers 18 Acid Resistance 18 Impact Resistance 18 Bushing Impact Resistance 19 Bushing/Stud Torque Test 19 Adhesion 20 Separator Test Methods 20 Test I – Ohmic Resistance 20 Procedure IA – Pre-Treatment 20 Procedure 1B – Ohmic Resistance 21 Test II – Dimension Measurement 30 Procedure IIA – Height and Width 30 Procedure IIB – Squareness 31 Procedure IIC – Backweb Thickness 31 Procedure IID – Overall Thickness 32 Test III – Determination of Volume Porosity 34 Test IV – Determination of Pore Size Distribution 35 Test V – Analyses for Impurities and Acid Extractables 36 Procedure VA – Acid Extraction 36 Procedure VB – Chloride Analysis 37 Procedure VC – Metal Analysis 39 BCIS-02 Rev Feb02 5.6 5.7 5.7.1 5.7.2 5.8 5.8.1 5.8.2 5.8.3 10 11 12 13 Test VI – Stiffness Measurement 39 Test VII – Determination of Puncture Resistance 41 Procedure VIIA – Globe Tester 41 Procedure VIIB – GNB (“Gould”) Puncture Tester 43 Test VIII – Wetting Properties 44 Procedure VIIIA – Acid Flotation Method 44 Procedure VIIIB – Acid Drop Absorption Method 45 Procedure VIIIC – Dry Charge Process Simulation 45 Sealing Compound 46 Electrolyte 47 Intercell Connectors 48 Post Straps 48 Plates 48 Handles 48 Tapered Terminal Posts 48 Side Terminals 49 BCIS-02 Rev Feb02 MATERIAL REQUIREMENTS 1.1 Materials Not Described Unless otherwise detailed in this specification, all material used in the construction of batteries shall conform to best commercial practices Active material, grid alloy or miscellaneous lead parts smelted from other batteries must be refined prior to subsequent use in new batteries STANDARD SPECIFICATIONS FOR PIG LEAD ASTM Designation B29-79(84) This standard covers pure lead of two grades for use in producing oxide for active material or alloying with various materials for grid alloys The chemical requirements are shown in Table I Table I Chemical Requirements % Element Silver (max) Copper (max) Silver & Copper (together) Antimony, Arsenic, Tin (Together, max) Zinc (max) Iron (max) Bismuth (max) Lead (by difference) 2.1 Corroding Lead 0015 0015 0025 002 001 002 050 99.94 Common Lead 005 0015 002 001 002 050 99.94 BCI Standard Reference Materials Standard Reference Materials have been developed by the BCI Technical Committee for use by lead and battery manufacturers Materials exist for 1, 3, and 6% antimony as well as leadcalcium-aluminum alloys with and without tin The analyses of these materials are shown in Table II Table II Chemical Analyses of BCI Standard Reference Materials Material Designation Element Aluminum Antimony Arsenic Bismuth Calcium Copper Iron Nickel Selenium Silver Sulfur Tin Tellurium
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