Robot Battery Leakage

Description/Symptoms of Issue:

EnerSys/NexSys battery leakage issue.

Cause:

We have received an official explanation from the manufacturer why such leaks may occur:

"Acid residues can remain trapped at the bottom of the acid injection chimney and get transferred up to the lid surface during use of the battery during operation. Acid residues can also get trapped between lid and box, causing marks on the external walls of battery, especially at the junction between box and lid. These batteries are leak proof, 100% of the products are tested during the production process. They can be safely used. When acid is found on the lid, a simple cleaning will take off excess acid, operation will stay safe. The procedure given as attachment to this knowledge article, explains how to best clean the product and which personal protective equipment should be used to do so."

What are the risks?

The manufacturer is working on improving their process of the nozzle cleaning. 

The residue is the result of insufficient cleaning in the production factory after electrolyte filling. Excess electrolyte appears due to internal temperature and pressure change when the battery gets charged.

Solution:

See attachment.