[RE-wrenches] Battery Electrolyte Level Measuring

[Ray Walters]

Hi William;

I agree with your original premise that checking levels is difficult by 
eye.  Also, I would add that many of my clients chronically over fill 
the cells, leading to acid loss and severe corrosion of the connectors, 
battery box, and floor.

Your float is an interesting idea, but personally I think you're 
inviting more acid contact not less, by putting the probe down into each 
cell.  This is similar to checking specific gravity.   I think a no 
contact method, like a laser measuring device would be the way to go.  I 
see several on Amazon in the $25 range.  I have a Bosch that's quite 
accurate; I tried it on some bottles with fluid in them, and it seemed 
to work well.  I'll try and remember to take out with me on the next job 
with FLA.

Ray Walters
Remote Solar

On 2/29/2024 2:12 PM, William Miller via RE-wrenches wrote:
>
> Friends:
>
> Thanks to everyone who responded to the original question.  The 
> information was valuable but did not directly approach the question.  
> I apologize if my replies hinted at frustration. I know everyone is 
> trying to help.
>
> This subject is important enough to me that I thought I’d take another 
> run at explaining what I am trying to accomplish:
>
> I do not like looking into battery cells.  It is dangerous. With some 
> of the larger battery banks looking into the cell requires climbing up 
> onto and kneeling on the tops of the batteries, increasing the danger 
> and adding discomfort and future wardrobe malfunctions.  Determining 
> electrolyte level by looking into cells gives inaccurate results.
>
> Safety glasses help but spilling acid on the unprotected area of my 
> face around the glasses is not ideal.  A face shield provides better 
> protection but when bending my neck sharply downwards the shield bumps 
> into my chest, is uncomfortable and obstructs my view.
>
> There has to be a better way!
>
> Here is where I am heading with an idea to provide a safer way to 
> measure electrolyte levels.  I have mocked up a prototype in my 
> kitchen to illustrate.
>
>
> The idea is a float with a scale attached.  The scale is calibrated to 
> show the desired fluid level and how much too low or high the level is.
>
> I was hoping someone had already gone down this road and I could 
> steal- I mean learn from- their ideas.
>
> I will keep trying to create something viable.  Already I have 
> something I can use, it’s just a bit hokey.  Ideally whatever I 
> conjure up can also be deployed while filling batteries by whatever 
> means you have at hand so the process can be safer, quicker and more 
> accurate.  Everyone who works with flooded batteries needs this.
>
> I hope this explanation makes more sense.
>
> William
>
> PS: I have seen electrolyte level gauges on the internet.  None that I 
> have seen quite fit the bill. Here is one 
> <https://www.flowsystemsusa.com/Battery%20Water%20Level%20Monitor%20Indicator%20Electrolyte%20Vent%20Cap.html> 
> that is not adjustable but comes in two fixed levels.  If you know of 
> a product that does what I need, or at least can spark some 
> creativity, please let me know.
>
> PPS: Ideally whatever I come up with is cheap enough that one or two 
> can be left in place to allow checking levels at a glance.
>
> Wm
>
> Miller Solar
>
> 17395 Oak Road, Atascadero, CA 93422
>
> 805-438-5600
>
> www.millersolar.com <http://www.millersolar.com/>
>
> CA Lic. 773985
>
>
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