Safe Handling of Batteries

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Hydrogen Gas Production

How to safely house and vent batteries indoors or outdoorsWhen you connect a battery to a voltage source, electrons are pushed into the cells to recharge them. A battery that uses a liquid electrolyte will not be able to absorb further electrons in its fully-charged state, so the electrolyte will create bubbles of hydrogen gas. Gelled-cell batteries that are maintenance-free minimize hydrogen buildup.

The battery bank must be appropriately located for easy servicing and inspection with safety as the main concern. Do not store batteries in enclosed and locked locations unless there is ample ventilation. A pipe can be positioned upwards out of the battery room for the lighter-than-air hydrogen to escape into the atmosphere.

Rooms that have serpentine vents or long shafts may need a powered venting fan. These fans operate by a switch inside the inverter to control the voltage, the charge in turn indicating hydrogen production and turning on the fan.

Another way to control the emission of hydrogen gas is to have reformer caps (from Hydrocap Corporation ) to convert oxygen and hydrogen by-products into water which falls back into the cell. The net result is reduced hydrogen gas emission with lower battery water. Hydrogen reformer caps only control and do not completely eliminate hydrogen gas emissions, which still require additional ventilation.

Safe Installation of Batteries

Safe battery racking indoors on solid metal shelvesA big deep-cycle battery can weigh as much as 300 lbs (136 kg). Hence, the mounting frame or shelf must be strong enough to support it securely. There must be enough manpower during installation to lift and position the batteries correctly without tipping or spilling the acidic liquid electrolyte over anyone.

Apply the following rules for safe and proper installation:

  • Install batteries in a properly-insulated location that is sealed and locked. As the batteries have lots of stored energy, children or unauthorized personnel should not go near them.
  • Safe outdoor battery storage using a lockable metal cabinetDo not wear any jewelry, a watch or any metallic/conductive items when working with batteries. A spanner, wrench or even a socket may weld itself onto battery terminals immediately and become red-hot, causing battery damage, severe burns and even explosion.
  • Hand tools must be insulated with electrical tape to avoid direct contact with the live battery terminals.
  • All work and support structures like benches and shelves need to be sufficiently strong:  extreme care must be exercised when handling the heavy batteries.
  • Eye protection gear and rubber gloves must be worn when handling the batteries as electrolyte splashes can cause blindness. Old clothes or overalls are preferred.
  • Keep a can of 5 lb (2.3 kg) of baking soda handy to handle small electrolyte spills. Dust any spilled electrolyte immediately with baking soda to prevent aggressive fizzing and to neutralize the acid. Keep dusting with baking soda until there is no more fizzing.