BS 6604:1985 download.Code of practice for Safe operation of starter batteries.
1 Scope
This code gives recommendations on safety and health aspects associated with the handling, usage and charging of batteries for starting internal combustion engines.
It covers lead-acid, nickel-cadmium and nickel-iron types which are divided into two groups as follows:
a) lead-acid:
b) alkaline electrolyte types (nickel-cadmium and nickel-iron).
The code does not cover:
1) the design and construction of cells or batteries:
2) the health and safety aspects of cell and battery manufacture;
3) the use of batteries in potentially explosive atmospheres.
NOTE The title of the publication referred to in this code is given on the inside back cover.
3 Electrolyte
3.1 General
Electrolyte is corrosive and poisonous. It will cause burns and irritation if it comes into contact with the skin or eyes.
3.2 Precautions
a) Handle batteries with care and keep them upright.
b) Top up batteries to recommended level. Do not overfill.
c) Always use eye protection when working on batteries. If there is a risk of contact with electrolyte wear protective clothing, e.g. gloves, aprons, etc.
3.3 Emergency action
a) Lead-acid cells, Spillages should be neutralized with an alkali, e.g. soda ash, sodium carbonate, sodium bicarbonate. If none is available, dilute with copious quantities of water.
b) Alkaline cells, Spillages should be neutralized with boric acid. If none is available, dilute with copious quantities of water.
3.4 First aide
If electrolyte comes in contact with the skin, wash off with water immediately. If an electrolyte splash in the eye has occurred, flood the eye immediately and copiously, using an eye wash bottle or, alternatively, mains tap water. The eye wash bottles should be disposable sterile eye irrigators or sterile saline solution bottles; they should be provided in or adjacent to every place where topping up or maintenance is carried out.
NOTE It is necessary to ensure that the sterile solutions are changed on a regular basis in accordance with the manufacturer’s instructions, as the sterile security has a time limit, usually 12 to 18 months. Non-disposable containers filled with mains water should not be used even if the water has sterilizing tablets dissolved in it. Algae will grow in water. particularly if the containers are translucent and the use of such water can set up serious infection of any electrolyte affected areas of skin or eyes.
Following irrigation of the eye medical advice should be sought immediately.
If electrolyte is swallowed, get the patient to drink plenty of water. Do not induce vomiting. Seek medical attention immediately.
3.5 Topping up cells
When topping up cells, only water of the specified purity should be used. The use of other substances may cause a dangerous reaction in the cells.
b) No smoking or naked flames should be permitted in the charging area or within 1 m of the top of an open battery in other locations.
c) Avoid short circuits.
d) When making or breaking connections to a battery, e.g. charging or jump starting, first cover the vents of the battery with a damp cloth.
e) Some battery locations are in poorly vented areas (such as under seats or in the boot) especially on caravans. Take special care here to disperse explosive gases before making or breaking any connections.
f) The use of high-rate battery testers will draw high currents from the battery and this will always result in sparks when the connection is made or broken. Take special care to disperse explosive gases before using these testers. Make and break the connections firmly and cleanly to minimize sparking.
6 Handling and installation
6.1 General
Batteries are generally very heavy. Care should be taken when handling to ensure that electrolyte is not spilled and that cells do not sustain mechanical damage. Batteries are normally fitted with labels giving safety and technical information. These should not be removed or obscured.
6.2 Precautions
a) Ensure that all electrical equipment on the vehicle is switched off.
b) Correct lifting methods and equipment should be used.
c) Where metallic lifting equipment is used, take care not to short circuit the battery terminals.
d) Ensure that the battery is correctly located in its position on the vehicle, and that any restraining devices are secured. Do not over-tighten.
e) Observe the correct polarity when making connections to the battery terminals, these connections should be clean and secure.
7 Routine checks
The following routine checks should always be made.
a) Check electrolyte levels and top up with water in accordance with the battery manufacturer’s instructions where necessary.
b) Check bolted connections for tightness and ensure that they are clean and efficient.
c) Inspect cable insulation for wear or damage. Replace if necessary.
d) Apply hand brakes and switch off all accessories.
e) Keep sparks and flame away from both batteries. Do not smoke.
9.3 Procedure for cases where the systems have the same frame (earth) polarity
a) Connect the live (non-earthed) terminal of the good battery to the live (non-earthed) terminal of the flat battery.
b) Connect one end of the second lead to the frame (earth) terminal of the good battery.
c) Connect the other end of the second lead to a suitable unpainted metal point on the chassis or engine of the other vehicle or equipment, away from the battery, carburettor, fuel lines or brake pipes.
d) Ensure that leads and hands are well clear of any moving parts.
e) Start the engine of the vehicle which has the good battery and allow to run for about 1 mm, or switch on the boost charger for about 1 mm. With this engine still running, operate the starter on the vehicle which has the flat battery and allow that to run for about I mm.
I) Disconnect the leads in reverse order as in 9.3 c), 9.3 b) and then 9.3 a).
9.4 Procedure for cases where the systems have opposite frame (earth) polarity
a) Connect the frame (earth) terminal of the good battery to the live (nonearthed) terminal of the flat battery.
b) Connect one end of the second lead to the live (non-earthed) terminal of the good battery.
c) Connect the other end of the second lead to a suitable unpainted metal point on the chassis or engine of the other vehicle or equipment, away from the battery, carburettor, fuel lines or brake pipes.
d) Ensure that leads and hands are well clear of any moving parts.
e) Start the engine of the vehicle which has the good battery and allow to run for about 1 mm, or switch on the boost charger for about 1 mm. With this engine still running, operate the starter on the vehicle which has the flat battery and allow that to run for about 1 mm.
f) Disconnect the leads in reverse order as in 9.4 c), 9.4 b) and then 9.4 a).
10 Repair
Having regard to the wide range of hazards which can occur in the repair of batteries, this work should only be carried out by suitably trained persons in accordance with the manufacturer’s instructions.