Technical Guide

Lead-Acid Batteries

Making battery
technology
easier to
understand

European Edition 3

Page 1
 Exide Technical Guide to Lead-Acid Batteries

Making sense of modern

battery technology
With the battery industry changing faster than ever customers. Discover how the market is moving forward,
before, Exide has produced this useful guide to make Helsinki make better-informed decisions and offer expert
Oslo
lead-acid batteries easier to understand. Exide is a recommendations to your customers. Even if you work
leading original-equipment manufacturer and is always with batteries regularly, hopefully you will still learn
quick to bring the latest innovations
Mölnlycke to its aftermarket something new.

Contents
Rotterdam
Vejle Moscow

Manchester
3Bad Lauterberg 16 Pinsk
35
Exide serves the A new generation Stock management
European of batteries and maintenance
aftermarket Poznan

4 18 0 3 6 36
9 12

Herblay Büdingen Prague

The vital component Manufacturing plants
Workshops get ready Recycling
Gennevilliers in modern vehicles for the Start-Stop
Recycling plants
aftermarket
Additional distribution centres
Esteban 5 20
European headquarters
37
Milan
How the battery Longer life batteries Terminology guide
Bonmati Romano di Lombardia
works harder than for Main sales offices
heavy-duty
ever before commercial vehicles

La Cartuja 6 22 38
zuqueca A look inside the box Considerations for CV The power of
applications Exide’s brands
ares

7 24 77 39
760
Carbon Boost Dual Battery System Exide – OE
batteries designed for Scania

8 26 42
Battery types and Exide Motorbike & Apps and mobile
their applications Sport Batteries product information

11 28 77 43
Lithium-ion vs Supply Batteries 760 New standards for
Lead-Acid for marine and leisure on-shelf and online
Dubai communication

12 31 44
Product life and Battery chargers for Exide Battery Range
performance workshops and
end-users

14 32 48
The road ahead A second century of Exide Transportation
48 V > 400 V > 500 V
innovation – driving a &
V 12 V 12 V
better future GNB Industrial Power

Page 2
 Exide serves the European aftermarket
with strong regional battery brands and local representation

Oslo Helsinki

Mölnlycke

Vejle Moscow
Rotterdam
Manchester
Bad Lauterberg
Pinsk

Poznan

Herblay Büdingen Prague Manufacturing plants

Gennevilliers Recycling plants
Additional distribution centres
San Esteban European headquarters
Milan
Bonmati Romano di Lombardia Main sales offices
Madrid

Azambuja La Cartuja
Castanheira Azuqueca
Manzanares

> Benelux > Italy > Nordics

> France Responsible for... Responsible for...
Adriatic countries Baltics
Responsible for...
Macedonia Iceland
Algeria
Morocco
Hungary
> Poland > Russia & Belarus
Romania
Tunisia
Serbia Responsible for... > Portugal
Africa (other French Azerbaijan Responsible for...
Bulgaria
speaking) Armenia Angola
Greece
> Germany Turkey Czech Republic Cabo Verde
Middle East Georgia
Responsible for... > Spain
Austria Egypt Kazakhstan
Switzerland Africa (English Kyrgyzstan > UK
Moldova Responsible for ...
Dubai
speaking)
Tajikistan Ireland
Turkmenistan
Slovakia
Uzbekistan
Ukraine

Global brand... Exide‘s regional premium brands...

Page 3
Exide Technical Guide to Lead-Acid Batteries
The vital component
in modern vehicles
The lead-acid battery has come a long way since that
pivotal point in car manufacturing history, when the
alternator was introduced in the early 1960s. Previously,
the number of electrical devices in a vehicle was limited
by the older DC generator, or dynamo as it was also
known.
Although early alternators had a much lower capacity
than those fitted in today’s vehicles, it was enough to
allow car manufacturers to introduce more electrical
devices to their vehicles.
It is difficult to imagine now how great the desire was for
something as simple as a radio or electric windscreen
wipers. And it did not stop there. Electrical circuits and
motors continued to replace manually operated handles
and levers over the years.
More driver controls and comfort devices have placed
more strain on the battery. Although still referred to as an
SLI (Starting, Lighting, Ignition) battery, its role has
become more vital to make everything in modern cars
work correctly. Today’s battery is expected to do so much
more than before, while remaining the same size and
weight as it was all those years ago.
Page 4
The cavernous space under the bonnet of a classic car
was soon filled with a vast array of new electrical and
mechanical components. At the same time, the trend was
towards sleeker, more compact body styling. Efforts
towards better fuel economy also meant that every gram
of each component counted towards the car’s overall
running cost.
As a world-leading manufacturer, Exide has constantly
met the challenges to make batteries better, smaller and
lighter. As a trusted partner, Exide works with major
carmakers to produce OE batteries that
fulfil the specification, deliver
reliable performance and
have excellent lifespan.
With over 60 technical engineers,
advanced research facilities in Europe and
the USA, and an increased R&D budget, Exide is
designing better batteries for today and
tomorrow.
Exide applies the same dedication to the manufacture
and supply of aftermarket batteries – a vital component
in modern cars. It is important that both installers and
end-users replace batteries with the best-quality
matching original part.
How the battery works much harder than ever before

50 years The past Today

ago 10 years

Basic electrical devices that
included lighting, radio and
window wipers
Over 100 control units, including climate control, electric
windows/mirrors/seats, mobile communications, satellite
navigation, high-quality sound/vision entertainment, enhanced
safety features, automatic sensors, Start-Stop battery
management control...

Did you know?

In 1900, the Electric Storage Battery Company developed
a battery of greater capacity and less weight for electric
taxicabs. It was the first to bear the name Exide, short for...

Excellent Oxide

Page 5
Exide Technical Guide to Lead-Acid Batteries
A look inside the box
The battery is one of the most important car components,
yet what is inside the box is rarely seen. By looking at
how a lead-acid battery is made, we can understand the
differences between various technologies and pick the
right battery for our needs.
Lead Plates
No other material, synthetic or natural, comes close to
the unique properties of lead, which has formed the
essential building block of rechargeable batteries for
the past 150 years. It is also very easy and economically
viable to recycle again and again. To give the material the
mechanical strength required for high-quality batteries,
battery manufacturers such as Exide use a lead-calcium
alloy for both positive and negative grids, so-called
“calcium-calcium”, essential for maintenance-free
batteries.
Traditional grids are gravity cast, a method of placing
molten lead alloy into a mould before leaving it to solidify.
This technique is still relevant for the thicker plates used
in deep-cycle AGM and GEL batteries. In more recent
years, starter batteries are using new thinner grids, which
create a larger surface area without increasing the size of
the battery. This provides more starting energy.
Grid Active Material
Manufacture Pasting
(lead-calcium-alloy) (lead-oxide)
Flooded Battery
3DX grid Negative plate example
(Expanded Metal) sponge lead (Pb)
AGM Battery
Framed grid Positive plate example
lead dioxide (PbO2)
Page 6
New manufacturing processes have emerged that rely
on a rolled lead alloy strip. One method is where punched
grids are obtained by pressing out metal scrap that is
later recovered by re-smelting. Exide was one of the first
European producers to refine an alternative method with
its 3DX Grid (Expanded Metal), where the lead alloy is slit
and then very precisely stretched. The re-processing of
punched-out scrap is eliminated and the reinforced 3D
diamond mesh ensures that the active mass stays fixed
on the mesh, resulting in better electrical performance
and longer lifespan.
Grids are then pasted with the active materials using
lead-oxide powder as the main ingredient. The positive
and negative plates, now referred to as electrodes,
are assembled in alternating sequence, set apart by
microporous separators to form an individual cell. The
separator prevents the plates from touching and causing
a short circuit, yet still allows ions to freely flow back and
forth. After charging, the positive plate becomes reddish-
brown, indicating the presence of lead dioxide (PbO2),
while the negative plate turns into grey sponge lead (Pb).
Individual Plate Completed Cell
Finishing Assembly
Alternate +/- plates
Microporous separator
Absorbent Glass Mat
(AGM)
Each cell produces 2.16 volts, regardless of the
plate size and quality. Modern automotive batteries
consist of six cells connected in series to produce a
total of 12.84 volts (6V batteries still exist but only on
older vehicles).
77
6 x 2.16 volts = EA770 760
12.84 volts
www.exide.info/ea770

EX2FF317
Exide introduced its groundbreaking Carbon Boost technology, which enables batteries to
recharge up to 1.5 times faster. How does this work?

During discharge, non-conductive sulphate particles

The Carbon Boost Effect
Without Carbon Boost
progressively cover the negative plates, isolating
them from the electrolyte. This means a lot of the
energy intended to recharge the battery is needed
to dissolve the sulphate, which makes charging less
efficient. The high-surfaced carbon additives in Exide’s
With Carbon Boost
Carbon Boost batteries provide superior conductivity,
dissolving the sulphate particles much faster.

Carbon Boost has improved charge

acceptance and recharges up to 1.5 times
faster than standard batteries. Battery
SUPER FAST
RECHARGE
failure remains the number one cause of
car breakdowns, and fast recharging considerably
reduces this risk, helping the battery retain a healthy
The plates are Sulphate is reduced due to
covered with sulphate Carbon Boost technology state of charge for longer.

Carbon Boost is available in Exide’s Premium LV and StrongPRO CV batteries

Exide Premium Carbon Boost Benefits Negative plate: Patented Labyrinth

›› 30% extra starting power 3DX grid with for extreme safety
Carbon Boost
›› Recharges up to 1.5 times faster
›› Ideal for highly equipped cars with Plate:
powerful engines and demanding 3DX grid enveloped
with high-
electrical needs performance
›› Ideal for extreme weather and urban polyethylene
separator
driving conditions
›› Original-equipment experience inside
›› Meets OE requirements
›› Comprehensive range covering around 90%
of car parc

SUPER FAST 3DX GRID SUPERIOR SUPERIOR EXTREME

RECHARGE TECHNOLOGY POWER EQUIPMENT CLIMATE

Page 7
Exide Technical Guide to Lead-Acid Batteries

Lead-Acid battery types

and their applications
Conventional AGM (Absorbent
(Standard Glass Mat)
Flooded) Starter Batteries
Batteries Instead of the conventional
This is by far the most polyethylene separator,
common automotive battery the plates of AGM batteries
today. The name ‘flooded’ are enveloped with a glass
refers to the plates being immersed in an electrolyte made mat that absorbs the
from 36% sulphuric acid and 64% distilled water. Thanks electrolyte and maintains
to the lead-calcium alloys of the grids, Exide car batteries direct contact with the
show very little water consumption. The individual plate’s active material.
cells are no longer accessible through individual plugs, This greatly enhances both
protecting against accidental acid spillage in normal discharge and recharge
motoring and so avoiding unnecessary servicing. efficiency, resulting in high
performance engine starting
and high cycle capabilities.
The physical bond between the battery components
and the container makes AGM spill-proof and the
most resilient battery to vibrations and tilting at high
inclinations.

The Exide Premium Carbon Boost battery features a

heat-sealed double lid with a patented labyrinth for
unbeatable security, ensuring a safe flow-back of acid
particles that is designed to withstand the rollover test.
Provided the starter battery is not subjected to long
periods of low charge, it will have a long service life and AGM can be used for Start-Stop cars with regenerative
excellent performance throughout. braking and coasting, and as a high-endurance starter
battery for utility and emergency light vehicles. Other
applications include off-road, motorbikes and marine/
leisure, dual start/supply.

Page 8
EFB (Enhanced GEL Batteries
Flooded Battery) Exide invented the
Batteries patented GEL battery
technology under the dryfit®
Developed by Exide in
trademark.* Instead of being
partnership with major
in liquid form, the electrolyte
European car manufacturers,
is thickened into a gel-like
the EFB battery combines
mass. The GEL battery is
3DX Grid plates with higher-
a highly robust energy-system with best-in-class deep
density active material and additives.
cycle properties, allowing unmatched safe depth of
The plate is contained in a polyethylene envelope and discharge to 90%.
combined with a polymat inlay, increasing cyclability.
Some manufacturers use the word ‘gel’ in the description
EFB is specifically designed for small to mid-sized
of their AGM products, but this partial use of the process
vehicles with Start-Stop, regenerative braking and other
does not come close to delivering the same performance
powerful fuel-saving features.
and benefits. Exide’s special patented design of pressure-
relief valves results in a fully sealed battery that can
be safely stored and used in almost any location or
environment, even transported by air. Crucially, GEL also
has the smallest volume and weight ratio for the amount
of Watt hours supplied.

As an energy supply battery, GEL is the ultimate choice

for many demanding applications including boats,
motorhomes and caravans. GEL batteries are also
essential in the latest commercial vehicles with dual-
battery systems, or indeed in any vehicle with extensive
electric power needs. The benefits of GEL make it popular
in construction, mining, agriculture and industry. The
technology is also used to provide remote power,
everywhere from local highways to the Arctic Circle.

Exide is currently working on achieving higher

performance levels through the introduction of carbon
additives, re-designed negative electrodes and new grids
to produce faster charging times and improved cycling
performance, making GEL an even more effective supply
battery.

*GEL was originally patented by Sonnenschein, which is now part of the Exide group

Page 9
 EXIDE BATTERY COMPONENTS & ASSEMBLY
Note that other battery maufacturers may use slightly different materials and configurations

CONVENTIONAL AGM EFB GEL

TYPE Definition Enhanced Flooded
Flooded Battery Absorbent Glass Mat Deep Cycle Battery
Battery

Features Grid Type 3DX Grid Framed Flat Cast Orbital 3DX Grid Cast Flat

3DX Grid 3DX Grid Cast Orbital 3DX Grid Cast Flat
Separator Microporous Absorbent Absorbent Polyethylene Polyethylene
Method Envelope Glass Mat Glass Mat Envelope/Mat Envelope
Electrolyte Liquid Absorbed Absorbed Liquid GEL

APPLICATIONS
LIGHT VEHICLE

Car Start-Stop
Start-Stop Start-Stop
Starting + Regenerative braking
+ Regenerative braking + Regenerative braking
+ Coasting mode
Van

Exceptional Exceptional
Specialist Starting
endurance endurance

COMMERCIAL VEHICLE

Delivery Truck

Long-Haul Truck

Bus & Coach

Separate supply
Starting Special applications
Construction
battery use

Agriculture

Specialist

BIKE

Motorbike

Moped
High Power Starting
Quad/Utility High Power Starting
+ Side Mounting
Starting + Side Mounting
Garden
+ Deep discharge

Jet Ski

Snowmobile

LEISURE

Separate supply
Motorhomes Starting & Supply Starting & Supply Starting & Supply
battery use

Caravan/Cabin Supply battery use Supply battery use Supply battery use

MARINE

Motor Boat
Separate supply
Starting & Supply Starting & Supply Starting & Supply
battery use
Sail Boat

Page 10
An introduction to
Lithium-ion vs. Lead-Acid batteries
What is Lithium?
Lithium is a chemical element with the symbol Li and
atomic number 3. It is a soft, silver-white metal and under
standard conditions, it is the lightest metal and the least
dense solid element. Because of its high reactivity, lithium
never occurs freely in nature, and instead, appears only
in compounds. Traces of Lithium can be found in water,
plant-life, food and even the human body. Commercial
extraction comes from specific rocks and granite with the
greatest abundance of lithium-containing minerals.
What is a Lithium-ion battery?
A Lithium-ion battery or Li-ion battery (abbreviated as
LIB), is a type of rechargeable battery in which lithium
ions move from the negative electrode to the positive
electrode during discharge and back when charging. They
should not be confused with lithium batteries, which
are primary (non-rechargeable) batteries that you may
recognise in daily use around the home in the form of an
AA/AAA dry cell or a button or coin cell battery used in
your remote car key for example.
Lithium-ion batteries are most commonly found in
portable electronics due to their high energy density and
low self-discharge. This battery type has undoubtedly
played a key role in the development and widespread use
of today’s mobile devices and laptop computers.
What are the main benefits and disadvantages of
Lithium-ion?
Lithium-ion offers the highest energy storage to smallest
weight/volume ratio of any kind of today’s commercially
available battery. Very fast recharge and longer life are
also very compelling arguments for this battery type.
These strong plus points come at a significantly higher
cost. This is due to more expensive raw materials, complex
assembly of components and high precision required in
the manufacturing process. Lithium-ion batteries pose
some unique safety hazards. A small fault or damage can
create an internal short-circuit and a subsequent build-
up of heat. In extreme cases an overheated battery can
possibly burst into flame. This situation is rare and is
protected against with a battery management system
to prevent operation outside each cell’s safe operating
range i.e. min-max charge, safe temperature etc.
How do Lithium-ion batteries scale up and challenge
applications traditionally performed by Lead-Acid?
Li-Ion batteries are made up from multiple cells
(typically 3.2V or 3.7V) that can be connected in serial
and parallel fashion to attain the required voltage. To
better understand this arrangement let us consider two
extreme ends of the spectrum. Exide’s Motorbike & Sport
Li-ion battery contains four cells of 3.2V each, connected
in serial to produce a total nominal voltage of 12.8V. At the
other end of the scale Tesla’s Model S electric car uses an
85 kWh battery pack containing 7,104 Lithium-ion battery
cells. It is worth mentioning cost at this point. The Li-ion
Motorbike & Sport battery costs around 3-4 times more
than a lead-acid equivalent. The list price of the Tesla
battery pack in 2015 was US$44,000.
Tesla Model S charging at the
Zoutelande dunes, in the Netherlands
Image: CC by David van der Mark
At the present time there are a few instances where
Lithium-ion high battery costs can be justified.
Motorsport is a good example, where the lightweight
properties of Lithium-ion can count towards winning
the race or not. Exide’s industrial division (GNB Industrial
Power) has proven a strong business case for investment
in Lithium-ion forklift batteries, resulting in impressive
cost and time savings.
Nobody can predict at this stage if, how, and when
Lithium-ion will enter mainstream use in the automotive
sector. Lead-acid battery technology has come a long
way over recent years. It still offers the only economically
viable solution to engine starting and the vast majority of
supply battery requirements. Continuous development is
pushing lead-acid technology beyond its previous limits
of performance and has even demonstrated success
in new, full electric modes of Personal Rapid Transit
[refer to page 33]. Of course, future developments in
Lithium-ion will be focused on reducing battery costs,
further improving safety and addressing the question of
recycling the end of life product. Within a decade we are
likely to see crossover between lead-acid and Lithium-
ion in a number of applications, but no great change of
dominance of one technology over the other.
Page 11
Exide Technical Guide to Lead-Acid Batteries

Product life and performance

Most common cause of breakdown

Electrical: Battery, Alternator,
50% Starter, Lighting

Bodywork, Steering, Brakes,

14% Chassis, Drive, etc.

Engine Management
13% (Injection, Ignition, Sensors)

8% Engine
50% of breakdowns
are caused by the 6% Tyres
vehicle’s general
electrical system 5% Fuel System

This percentage grows 3% Cooling, Heating, Air

as the level of
electrical equipment Exhaust system, Particulate
increases 1% filter, Catalyst
Source: ADAC Breakdown Statistics for Germany 2016

At 50%, electrical problems are the single biggest cause of environment can all have a negative effect on the battery.
breakdowns, according to the latest figures from Europe’s Occasionally a faulty alternator can take its toll on the
largest roadside breakdown service. In Germany alone, battery. Regular testing of both battery and starter/
over 640,000 call-outs per year are due to a defective alternator avoids most unexpected car breakdowns.
or discharged battery. If the driver is away from home
or desperate to get started, it results in a costly battery
replacement on the spot.

In many cases, issues with an aging or neglected battery

can be picked up during a service through a routine
battery test. Sometimes a simple charge with a good
battery charger is all that is required, but if the battery
needs to be replaced, it is far better done in the workshop.
The inconvenience of a breakdown is avoided, the risk of
losing valuable information from the on-board computer
is reduced, and the workshop makes the sale.

A shorter than expected battery life is often the result of

short-distance driving or the use of too many electrical
devices. Storage, handling, loose fitting and the Exide EBT-165P – Most popular battery, starter and alternator tester

Page 12
 Main reasons for Battery self-discharge
reduced battery life All lead-acid batteries suffer from self-discharge. The pace of this self-
discharge depends on the storage conditions and the technology.
Generally, the cooler the storage conditions, the slower the self-discharge.
Calcium-Calcium batteries such as conventional flooded (maintenance-
free) car and truck batteries have a lower self-discharge than Calcium-
Antimony conventional batteries (Hybrid) like Marine Dual, Marine
Equipment and some truck batteries with filling plugs for water top-up.
Short distance trips with
maximum loads This is important for both distributors and battery users. Distributors have
to make sure that the FIFO (first-in, first-out) rule is applied for stock
management. At the same time, the voltage of the batteries should be
regularly controlled: when the voltage drops to 12.4V, the battery needs to
be recharged to avoid shortening the battery’s lifespan and introducing
performance problems.

People who only use their

SELF-DISCHARGE OF BATTERIES
battery for short periods Shelf life at 20ºC
Incorrect application
during the year (such as Open Circuit
or short circuit Voltage
motorbike, motorhome,
caravan or boat owners) 12,8V
Calcium-Calcium
have to ensure that their batteries
batteries are fully
recharged before storing 12,4V
Hybrid
them away. They should batteries
also regularly check/
Loose fitting and recharge them during 10 18 Months
box damage storage time.

How temperature affects

engine starting
Available power Power required
Prolonged periods from battery to crank engine
of self discharge

Overcharging with
risk of drying out

Extreme
temperature

Page 13
Exide Technical Guide to Lead-Acid Batteries

The road ahead

Full electric cars are still a long way from entering the mainstream market. Small numbers of Mild and Full Hybrid cars
are also appearing, but Start-Stop (Micro-Hybrid) remains by far the most popular technology with car manufacturers.

Start-Stop Mild-Hybrid Full-Hybrid Electric

Micro-Hybrid Optional Plug-in type

12 V 48 V > 400 V > 500 V

12 V 12 V 12 V

Fuel/Power Input
Fossil* Fossil* Fossil* Electric Electric

Vehicle Propulsion
Full Engine Engine supported by Engine or Full Electric
electric motor electric motor
...especially coasting, ...subject to available
braking & stopping battery energy

Battery Technology
12 V AGM or EFB 48 V Lithium-ion > 300 V Lithium-ion > 300 V
Lithium-ion
12 V AGM or Li-Ion Auxiliary 12 V AGM or Li-Ion Auxiliary 12 V AGM or Li-Ion Auxiliary

Energy Efficiency
Start-Stop + Start-Stop + Start-Stop + Start-Stop +
Regenerative braking Regenerative braking Regenerative braking, Regenerative braking,
& coasting (optional) & coasting coasting & kinetic coasting & kinetic

Reduction in CO2

≤ 100%
2-10% 12-20% 15-30%

Subject to level of
renewable energy

Projection of 2020 European Light Vehicle Market by propulsion type

49% 1% 4% 2%
44% 44% 44% 44%
Standard Standard Standard Standard
Cars Cars Cars Cars

* Fossil fuels include: petrol, diesel and CNG Source for Market Projection: Eurobat 2014

Page 14
 CO2

L
EU Regulations for the
160g
reduction of CO2 130g

Start-Stop technology is favoured by most car 120g 95g

manufacturers to reach targets and avoid EU penalties

During a global push to reduce CO2 emissions through 80g Car manufacturers’ compliance
various forms of carbon tax, some regions, as net to 95g target: 95% by 2020
importers of oil, have much more to gain by conserving 40g 100% by 2021
energy. This explains why automotive development in
greener cars has been most vigorously pursued in Europe 0g
and Japan, where end-users in these markets are more 2000 2005 2010 2015 2020
attracted by the offer of better fuel economy.

Citroën launched the first commercially viable Start-Stop

cars in 2004. As a development partner and OE supplier
to Citroën, Exide produced the first AGM battery for these
new models. Other early adopters of Exide Start-Stop
batteries included BMW, Toyota and Fiat, plus many more
car manufacturers in the meantime. From those early
days, sales of new Start-Stop cars are overtaking standard
combustion engine models and there is now a growing
demand for AGM and EFB batteries in the aftermarket.
In an ever-changing world, Exide continues to develop
new batteries to enable future vehicles to reduce CO2
emissions even further and improve overall driving
efficiency.

Projected European LV battery units (million units) European CO2 Emissions

2015 2020 2025 from road transport
Li-Ion
High Voltage 0.3500% 1.4 3.0 EU-28
48V (Mild Hybrid) 0.05 0.4 1.0 845M Tonnes
Total Li-Ion 0.4 0.5% 1.8 2% 4.0 4.5% Germany France UK Italy Spain

Lead-Acid
Start-Stop 17.0 21% 35.0 40% 44.0 48.5% 155M 124M 109M 98M 76M
Accessible
technology
for the IAM
Fastest
growth:
AGM & EFB Source: Eurostat figures for 2014
Conventional 63.0 78.5% 50.0 58% 43.0 47% Start-Stop
Batteries
Total Lead-Acid 80.0 99.5% 85.0 98% 87.0 95.5%

Total (million batteries) 80.4 86.8 91.0

Exide launched the first Start-Stop batteries...

Exide estimates for Europe including Russia/CIS/Turkey.

AGM in 2004 & EFB in 2008

Page 15
Exide Technical Guide to Lead-Acid Batteries

A new generation of batteries

Exide Start-Stop AGM Exide Start-Stop EFB

Absorbent Glass Mat Enhanced Flooded Battery
Ideal for large cars, SUVs, vans and vehicles with Ideal for small to mid-sized cars with Start-Stop
Start-Stop and power-hungry electrical equipment and other fuel-saving features
x4
Key Performance Very high
Key Performance
Other AGM x3
High

Other EFB

120% 110%

Standard Standard
conventional conventional
battery battery
Power Cycle Charge Power Cycle Charge
Life Acceptance Life Acceptance

ABSORBENT REGENERATIVE SUPERIOR INTENSIVE 4 x STANDARD 3DX GRID REGENERATIVE SUPERIOR INTENSIVE 3 x STANDARD
GLASS MAT BRAKING POWER USE CYCLABILITY TECHNOLOGY BRAKING POWER USE CYCLABILITY

Today’s conventional car battery has come a long way,
but the tasks of starting the engine and supplying stored
energy for lighting, driving and comfort controls have
remained largely unchanged. However, the new
generation of Start-Stop cars puts far greater demand on
the battery to work harder and requires many more
thousands of starts during the battery’s lifetime.
The global shift led by European car manufacturers
towards Start-Stop cars required a totally new kind of
battery. Exide’s expertise and vast experience in stored
energy for automotive and industrial applications put the
company in prime position to develop Start-Stop batteries
designed to cut fuel consumption and reduce CO2
emissions.
In 2004 Exide launched the first European AGM
(Absorbent Glass Mat) Start-Stop battery, followed by
the first EFB (Enhanced Flooded Battery) battery in 2008.
Today Exide is a well-respected and leading supplier of
Start-Stop batteries to eleven of the main European car
manufacturer groups (see page 17).
On the outside, Start-Stop batteries appear very similar to
conventional car batteries, but the technology inside the
box is vastly different. Even entry-level Start-Stop
vehicles demand twice the endurance of the very best
premium battery. Larger cars with Start-Stop and those
featuring Regenerative Braking require up to 15% extra
power and three times the endurance level.
It is extremely important to respect the car
manufacturers’ specification. Always use an Original
Spare Part AGM to replace AGM, and EFB to replace EFB.
Incorrect fitment will reduce battery life and the
effectiveness of the Start-Stop system.

Page 16
 EXIDE START-STOP OFFER
Exide Car Brands Exide Exide’s IAM offer
Manufacturer OE
Start-Stop Group offer AGM AUX EFB
Auxiliary BMW
BMW

Battery
Mini
Mercedes-Benz
Daimler
Smart
Alfa Romeo
Designed by Exide to Chrysler
meet the latest Fiat Chrysler Ferrari
technical demands Fiat
Lancia
from car manufacturers, the new Auxiliary battery
provides voltage stabilisation during re-start operations. Ford Ford

Exide’s Auxiliary battery is proving to be a very cost- GM

Opel
Vauxhall
effective alternative to other solutions such as a DC-DC
Hyundai
converter. The product was able to withstand 250,000 Hyundai
Kia
cycles during testing, demonstrating excellent product
Jaguar
life expectancy. The mini-EN-shape terminals on this JLR*
Land Rover
battery are unique in the market.
Mitsubishi Mitsubishi
Peugeot
PSA*
Citroën
Renault
Renault Nissan
Nissan
Dacia
Image: Creative Commons by smoothgroover22

Suzuki* Suzuki

Toyota* Toyota

Audi
Bentley
Porsche
VW Group
Seat
Skoda
VW

Volvo* Volvo

* Special recognition of Exide supplier quality and awards for our factories

Exide is one of the largest OE manufacturers of
Start-Stop batteries, and its AGM and EFB ranges are
readily available as high-quality replacement parts for all
European Start-Stop cars.
The chart shown here gives a simple overview of Exide
Start-Stop battery types, covering a wide spectrum from
popular entry-level cars to high-end luxury models.
Image: Creative Commons by Jaguar MENA

Page 17
Exide Technical Guide to Lead-Acid Batteries

Workshops get ready for the

Start-Stop Aftermarket
Now that Start-Stop batteries are entering the
aftermarket, independent workshops can fully rely on
Exide’s support and products to compete with franchise
main dealers and battery specialists.

Exide listened carefully to the views of garage operators

before launching the first complete set of ‘task-specific’
battery workshop tools. These simple, flexible and
cost-effective solutions allow garages to exploit the
full potential of this rapidly expanding new market. No
two workshops are the same, so this approach enables
garages to buy only the tools they need to deal with new
Start-Stop batteries.

Award-Winning BRT-12 Battery Replacement Tool –

a simple solution for Start-Stop batteries

Synergy is our programme to simplify battery replace- It is time for all workshop operators to review their
ment in the latest cars. Micro-Hybrids are the fastest capability in replacing Start-Stop batteries. With Exide’s
growing segment of the car parc, with the batteries support, it is very easy to adapt quickly to this new battery
tied more closely to the electrical management system technology and expand your current business.
and the ECU. Some diagnostic equipment was not yet
Trust Exide to provide the independent aftermarket with
capable of addressing this use case, so Exide has been
high-quality Start-Stop battery products, expert advice
pushing for this to change.
and straightforward installation solutions.
We met with the diagnostic equipment providers
to explain the problems our customers have
been facing. Many of the providers have since
announced software updates to introduce
battery replacement capabilities, which is
great news for our customers.

Not all workshops have diagnostic

equipment, and that’s why we
also launched the BRT-12 battery
replacement tool. The BRT-12 lets
you clear battery fault warning
lights from the dashboard and
check current battery details,
and it costs around 80% less
than full diagnostic equipment.
Regular software updates will
continue to be provided by Exide
as new models enter the market.
Simply connect the device via USB
to your PC and download the new
data.

Exide BRT-12 makes it easy to register for

software updates to handle the latest
Start-Stop car models.

Page 18
 Test, charge or replace new Start-Stop batteries
with Exide’s workshop tools
> Is your workshop ready? Check your existing devices now for compatibility with Start-Stop cars.
> If you use diagnostic equipment, ensure your software is up to date and able to complete the job.
> Exide supports workshops with individual ‘task-specific’ tools available at a reasonable price.

OK

Start-Stop
Test Charge
Battery

Replace
Exide EBT-165P with Exide 12/7
Battery Tester Battery Charger
A modern tester with test report
printouts that works for all batteries,
Exide AGM or EFB A charger with unique built-in safety
features, suitable for standard, Start-
including those found in the latest Start-
Stop generation.
Aftermarket battery Stop AGM/EFB and GEL batteries.

Ah

Find Install

Unique QR codes and mobile

webpages provide full product
information, including features,
benefits and specifications. OK

FREE download for

OBD
ESC

iPhone, iPad and Android.

Exide Battery Finder App Exide BRT-12

for your smartphone
Search by car model, VIN or registration Find the right battery
number to find the correct battery fast. Web from your computer,
Catalogue using Exide’s best-in-
Exide battery catalogue powered by
class fitment lists. Visit
TecDoc in your pocket!
www.exide.com
Battery Replacement Tool
Most Start-Stop battery replacements do
not require special tools.
For occasional reset of the Car
Management System, Exide’s BRT-12 is an
affordable, easy-to-use tool.

Page 19
Exide Technical Guide to Lead-Acid Batteries

Longer life batteries for

heavy-duty commercial vehicles

One of the most recent advances in commercial vehicle

battery technology has been HVR® (High Vibration
Resistance), developed by Exide Technologies. This
feature offers unprecedented levels of reliability by
substantially absorbing vibration that is the main cause
of damage to the internal structure of the battery.

As an important OE partner to major truck manufacturers,

Exide developed the HVR® battery to solve a problem
created by the introduction of new exhaust after-
treatment equipment, required to meet EU regulations
for reducing emissions of nitrogen oxides and particulate
matter.
Recommend Exide HVR® for all situations where
The addition of the sizable new SCR catalyst and AdBlue ® endurance and the longest possible battery life are
tank has, in some cases, displaced prime factors. This technology is
batteries from the central chassis particularly valuable when used
New battery
to a much more vulnerable rear position to in construction, agriculture/
chassis location, where increased accommodate forestry, or in regions with poor
diesel exhaust
vibrations would reduce the aftertreatment
road conditions and harsh
lifespan of the product. Exide system environments.
HVR® batteries limit the effects
A modern commercial vehicle is
of vibrations, and provide the SCR Catalyst
a large investment. Companies
performance and life expectancy
making such a major purchase
the vehicle operator demands and AdBlue® Tank need to ensure that their vehicles
expects.
are kept on the road as much as
Exide has also introduced a new possible. Unforeseen breakdowns
sealed lid design that offers a and servicing delays can have
number of benefits such as a longer Batteries expensive consequences for the
shelf life and spark- and spill-proof vehicle owner, so it is essential
handling. to only fit the best ‘original part’
Rear chassis high replacement.
Exide was the first to introduce this vibration point
technology into the independent Exide’s commercial vehicle
aftermarket, allowing you to batteries are amonst the most
extend your service offer to the newest truck fleets. But powerful on the market. HVR® technology helps our
these batteries provide significant advantages to your batteries go the distance, keeping your vehicles on the
customers’ existing vehicles too. road and reducing total cost of ownership.

Page 20
 European emission standards PM (g/kWh) Particulate Matter

CV
for trucks and buses Euro 1
1993 0.30
This table summarises the
emission standards and their Euro 4 Euro 5 Euro 6
2006 2009 2013 0.20
implementation dates for new
type approvals. A different set
Euro 2
1996 0.10
of standards apply to passenger
Euro 3
cars and light commercial 2001

vehicles. 0.01
7 6 5 4 3 2 1 7
0.4
NOX (g/kWh) Nitrogen Oxides

The Cost of High Emissions for Fleet Operators European Low-Emission Zones (LEZ)

> Higher Fuel Costs
> Higher Road Taxes
> Higher Toll & Parking Charges
> Higher charges to enter Low Emission Zones
These are the key economic factors driving operators to
upgrade their fleets by purchasing new Euro5/6 vehicles,
fitting new engines or approved filter systems.
Currently over 220 cities and towns in fourteen countries
across Europe operate or are preparing to introduce Low-
Emission Zones (LEZ’s), to help meet EU health-based air
quality limit values.
Restrictions are applied mainly to older diesel-engine
trucks and buses, although in some cases cars too. This
means that vehicles may be banned from a LEZ, or a
charge is made to enter the zone when emissions exceed
a set level.

Example: Greater London - the largest LEZ in the world.

Daily charge over €550* for a truck over 3.5 tons gross
weight registered as new before 1st October 2006.

*Approx. exchange rate at the time of writing. Source: Transport for London

Page 21
Exide Technical Guide to Lead-Acid Batteries

Considerations for CV applications

Logistics is more important than ever, with customers
expecting faster and more predictable deliveries. In this
competitive environment, fleet owners are focusing on
total cost of ownership. After all, when a truck is off the
road, it leads to customer dissatisfaction, unused labor
and capital, and potential fines and penalties.
Exide designed its battery range to reduce the risk
of breakdowns and gives customers a competitive
advantage. You get market-leading performance, lower
total cost of ownership and battery options for any use
case.
As a true expert in OE batteries, Exide helps you select
the right battery. For fleet owners and installers alike,
it is vital to make the right choice for the conditions
of use. Three important
criteria to consider in battery
performance are: vibration
resistance, cycling endurance Vibration
and cranking power. Resistance
Three main factors when selecting the
right battery:
Vibration resistance: For trucks with rear-
chassis battery installations (e.g. Euro 5/ Euro
6 trucks), robust and high-vibration-resistant
batteries are mandatory to avoid breakdowns.
Vibration resistance is also required for any
vehicle operating on bad roads or rough
terrain.
Cycling endurance: High cycling endurance
is important in batteries for long-haul trucks
with life on-board, commercial vehicles
doing intensive urban deliveries, and any
commercial vehicle with extensive energy
requirements. This maximizes battery lifespan
and ensures a safe battery start.
Cranking power: High cranking power allows
for engine starts in cold climates and is
required for many power-intensive vehicles in
agriculture and construction.

Cycling Cranking
Endurance Power

Vibration Vibration Vibration

Resistance Resistance Resistance

Cycling Cranking Cycling Cranking Cycling Cranking

Endurance Power Endurance Power Endurance Power

Page 22
Page 22
 Reinforced container wall Labyrinth integrated into the lid with
with additional ribs* flame arrestor and central degassing
outlet for maximum safety

3DX negative grids with

Carbon Boost™ for super-fast
recharge and improved cycling

Additional hot melt

spots locking the
cell group*
New extended side
and top fixation*
Framed positive grids with heavy-duty Bottom plate
polyethylene separator and glass mat for adhesion
homogeneous compression for extra fixation*

* Latest generation of Exide’s leading HVR® design, meeting V4 requirements (EN 50342-1:2015)

New EN50342-1 Standard: V4 tests much tougher

Even more demanding than OE customer specifications
> New edition of European standard officially
Old single axis test New three axis test
released in late 2015

Supersedes 2006 edition and 2011 amendment.

> New V4 vibration test

A more rigorous test based on 3 axis motion

representing ‘real life’ conditions. V1-3 tests were
based on single axis vibration only.

> New endurance test

New E2 test replaces the previous E4 test for

standard lead-acid batteries. This new level is more
demanding, requiring test batteries to complete New endurance test
at least 150 cycles (at 50% DoD) without any
intermediate full recharge.

> Exide meets the challenge

150
cycles
50%
Exide’s R&D team has worked hard to make the
best even better, by developing a completely new
HVR® product. Exide is one of the first battery
manufacturer to meet the highest new V4 standard. Depth of Discharge

Page 23
Dual Battery System designed for Scania

The Dual Battery System was developed by Exide
Technologies in association with its customer Scania,
for intensive truck use and as the ultimate solution for
reliable starting.
In contrast to the classic layout – two standard flooded
truck batteries providing energy for both engine start and
supply functions – the Dual Battery System includes two
Orbital AGM batteries for cranking the engine at start-up,
plus two GEL batteries for on-board power supply. This
optimised technology matches the best battery type
with each specific function. The Orbital AGM batteries
supply full power to crank the engine and then restore a
full charge before switching off. When the engine is off,
power is provided exclusively by the GEL batteries, which
ensures the Orbital AGM batteries remain fully charged
for the next engine start.
The benefits of the Dual Battery System are clear. The first
advantage is improved starting reliability, as the power in
the Orbital AGM units is reserved solely for starting the
engine. This means reduced truck downtime, as these
batteries are always ready. The GEL batteries provide
a better power supply for devices such as the heater,
television, fridge, etc. – items which need to run during the
night, when the vehicle is off the road. Another advantage
is the weight saved in comparison with conventional
batteries, leading to reduced fuel consumption. The
dimensions of the Dual Battery System are the same as
the classic system, so there is no impact on housing them
in the vehicle.
The Dual Battery System has been successfully integrated
into the new Scania Streamliner truck range and will be
extended to other truck manufacturers in the near future.

Page 24
Traditional Truck Battery Configuration New Dual Battery System

Conventional Flooded Start and Supply Orbital AGM Start GEL Supply

Safe Level of Discharge

Recommended limits for optimum battery life*

50%
In normal day-to-day situations, the traditional configuration of
heavy-duty batteries providing both start and supply functions
continues to serve vehicle operators well. Experienced drivers are
aware of and respect the limits of on-board power.
75% 90%
Exide’s Dual Battery System copes far better with any unscheduled
delay in transit. The GEL battery set offers deeper discharge to
supply power when the engine is off, while the independent Orbital
AGM set remains fresh and ready to provide reliable starting power.

Benefits of each battery type

Conventional Flooded Orbital AGM Start GEL Supply

Standard configuration Faster recharge Greater supply capacity
Lower initial cost More reliable starting Extended periods
Longer battery life between recharge
Longer battery life

*Calculations based on an average battery life of 300 cycles and depth of discharge at 20º C.
Beyond these recommended levels: Deeper discharge = shorter average life. Shallower discharge = longer average life.

GEL is the ideal choice of battery as a reliable secondary power supply for any
vehicle with essential on-board equipment
©Au Morandarte CC BY-SA 2.0

Emergency vehicles carrying Urban buses with extensive use of Mobile cranes, power lifts and all
pumps, winches and electrical Closed-Circuit Television security specialist task vehicles
rescue equipment and passenger information
systems

Page 25
Exide Technical Guide to Lead-Acid Batteries

Exide Motorbike &

Sport Batteries –
ready to use or fast fill

Although commonly known as bike batteries, we use Maintenance Free

the same technology for jet skis, snowmobiles, quad
bikes, golf carts and lawn mowers. With the exception
of snowmobiles, most of these vehicles are used much
more frequently during the spring and summer months.
This means the batteries need to be able to handle long
periods without being used.
Exide has developed its Motorbike & Sport battery range
along distinct product lines. Because motorbikes are a
passion, many owners like to self-fit their battery, so it’s
important to maintain that option.
Factory Sealed
Factory Sealed is our top-of-the-range battery, which
comes filled, charged and ready to use, like most
automotive batteries. The battery is available in both
AGM and GEL, depending on your requirements. The GEL
version features the original GEL technology invented by
Sonnenschein®, now part of Exide. The battery provides
maximum cycle life and deep-discharge protection, ideal
for vehicles with power-hungry electrical equipment.
The AGM battery offers the highest power and extended
cycle life. Both are spill-/leak-proof and highly vibration
resistant, ideal for high-class motorcycles, powersport
and off-road vehicles.
This AGM battery comes in dry form. This has obvious
advantages for shelf life, as the life cycle of the battery
does not begin until it is filled and charged. The battery
is maintenance free, offers impressive performance and
is suitable for most applications. The design is leak-proof
and vibration resistant but not recommended for side
mounting. A six-pack acid bottle is included which allows
the user or stockist to quickly fill the battery with precise
quantities of acid.
Conventional Flooded
This is a popular choice for entry-level and older vehicles
with standard power needs. Acid filling is required, using
Exide’s simplified acid filling process. Conventional
batteries are supplied with cell plugs that need to be
fitted before installation and re-opened for occasional
water topping up.
How does acid filling work?
An acid pack is included with the battery when required.
This allows the user or stockist to quickly fill the battery
with precise quantities of acid by simply inverting the
pack and pressing it down into the cell openings. The foil
bottle seal is pierced in the process making the whole
operation quick, safe, easy and clean. When all the acid
has gone from the bottle, wait at least 30 minutes while
the acid is being absorbed, then the battery lid or plugs
can be fitted.

Page 26
Exide Li-Ion
Exide is speeding up your passion. It has launched a
new lithium-ion Motorbike & Sport battery range for
those who demand the ultimate riding experience. The
battery’s ultra-lightweight design reduces the overall
weight of your bike, enabling faster acceleration and
better performance. It has very low self-discharge, ideal
for starting your engine after long periods off the road.
Exide Li-ion can be installed in multiple positions and
comes with first-class safety features.

Benefits
> Ultra-lightweight – up to 80% lighter than lead-acid
batteries

> Very low self-discharge – long shelf life and perfect

for seasonal use
State-of-Charge (SoC)
> Super-fast recharging
indicator
> Extreme cycle life – more than 2000 cycles

> First-class safety features

> Multi-position mounting – even upside down

> Ready to use and maintenance free – just install and

forget

> State-of-charge indicator for regular checks at one

glance
3 Lights 2 Lights 1 Light
> Covers the majority of parc – spacers included for
Battery is fully Battery can still Battery needs to
more fitment possibilities perform cranking, be recharged
charged
but recharge is
SoC ≈ 10%
recommended
OCV≈ 12.9V
Li-ion batteries require special chargers with
SoC ≈30%
charging profiles adapted for this technology. Do OCV ≈ 13.05V
not use a lead-acid battery charger, it will damage
the battery.

Exide 12/2 Li-Ion charger

is created specifically for
Exide Li-Ion Motorbike &
Sport batteries, bringing Open-circuit voltage
extended battery service (abbreviated as OCV ) is
life and maximum safety. the difference of electrical
potential between two
terminals of a device
when disconnected from
any circuit.

Page 27
Exide Technical Guide to Lead-Acid Batteries

Supply Batteries
for marine and leisure

Supply batteries are sometimes referred to as deep-cycle

batteries or leisure/multi-fit batteries. They are commonly
used in motorhomes, caravans and boats to provide
stored electricity in remote locations without access to a
campsite’s or marina’s main power connection.

Choosing the right supply battery is subject to more

variables than with a starter battery. A car battery, for
example, is relatively straightforward, simply matching
the battery specification to the correct car model, engine
and year. Supply batteries are not defined by the vehicle
or vessel itself, but by how the owner uses their on-
board power supply. Basically, the amount of electrical
energy consumed and the length of periods away from a
recharging point determine the right choice. Not having
enough stored energy is inconvenient at best. In the
case of a boat at sea, it could even be life-threatening if
navigation systems are unavailable.
Starter batteries are made with thinner plates allowing
more plates to be fitted in each cell. This is necessary to
deliver better Cold Cranking Amperes (CCA) performances,
essential for quick bursts of high energy to crank the
engine. Supply batteries are designed with thicker plates
that provide a deeper and longer discharge. To use a
sporting analogy, think of the starter battery as a sprinter
and the supply battery as a marathon runner.
Exide Technologies has a well-established reputation in
the marine and leisure markets. As an OE manufacturer,
the company also supplies a wide range of quality
aftermarket batteries to meet individual users’ needs.
Exide Dual and Dual AGM are multi-function batteries
that support engine cranking and supply-power
requirements. While Exide Dual is a very popular choice
for light to medium users, the AGM variant offers the
fastest recharge of any supply battery type. Exide’s
Equipment GEL is the ultimate supply battery, offering
excellent power to weight efficiency and, as a result, the
best fuel efficiency.
A unique advantage of Exide supply batteries to resellers
and end-users is the specification and labelling in Wh
(watt-hours) rather than the Ah (amp-hours) traditionally
favoured by other manufacturers. This greatly simplifies
calculation of the on-board electrical equipment and its
typical daily usage. For example, a 25 watt lamp switched
on for 4 hours equals 100Wh. By adding up the watt-hours
of all the devices used between recharging, and adding
a recommended safety margin of 20%, it is quite easy to
find the right combination of one or more Exide batteries
to meet your power needs. See the example shown in the
‘Supply needs calculator’ on the next page to understand
how it works.

Did you know?

There are more than 5 million leisure vehicles and
almost 6 million recreational boats in Europe.*

*Source: European Caravan Federation & International Boat Industry

Page 28
 Supply battery options and energy-needs formula
Starter Supply (Deep Cycle)
Battery Batteries
Thinner plates allows Thicker plates improve the cyclability for deeper and longer
for more plates in the discharge.
battery. Better for
short bursts of high Available as Dual/Dual AGM or dedicated Equipment GEL
energy needed for for starting and supply needs for best depth of discharge
starting. and longest life.

Start Start
plus equipment load equipment load only

Car Engine cranking

and standard
vehicle electrics

Caravan Cabin lighting and appliances Lighting and

appliances

Motorhome Engine cranking Engine cranking plus Lighting and

and standard cabin lighting and appliances appliances
vehicle electrics

Boat Engine cranking Engine cranking plus + specialist

cabin lighting and appliances marine
equipment

Average Life
Recommended safe levels of battery discharge*

300+ Standard Start Exide Dual Exide Dual AGM Exide Equipment Gel
cycles

25%
based on
recommended
25% 40%
Depth of 50%
75%
Discharge 75% 90%
(DoD)
100%

Beyond these recommended levels: Deeper discharge = shorter average life. Shallower discharge = longer average life. *Estimates based on depth of discharge at 20∘C

Supply needs calculator Exide supply battery options

Usage
between
recharge
W × h = Wh
Watts hours Watt hours
Exide Dual Exide Dual AGM** Exide Equipment Gel**
25 × 4=100 ER450 EP900 ES1300

300 × 1=300
40 × 3=120
35 × 2= 70
80 × 6=480 450Wh/95Ah 900Wh/100Ah 1300Wh/120Ah

3 x 23kg 2 x 32kg 1 x 39kg

Total devices = 1070
69kg 64kg 39kg
Safety margin × 1.2 Fastest recharge Smallest volume/weight
time ratios available

Required Wh = 1284 1350 Wh 1800 Wh 1300 Wh

**
DNV GL international certification: Batteries approved for marine safety and functionality.

The rated energy in Wh is calculated based on the safe DoD indicated above: 100Ah in AGM is equal to 900Wh because of allowed DoD is 75% (otherwise 100Ah at 12V would be 1200Wh)

Page 29

The illustration above of a typical motorhome shows the
electrical power needs of a typical leisure vehicle. The
starter battery provides a regulated supply of energy for
the vehicle’s standard electrical devices, but a separate
supply battery is installed to deal with the additional
loads on the AC and DC circuits.
The major benefit of a supply battery is the depth of
discharge between recharging. When the vehicle is in
motion, the battery is replenished by sharing energy
generated by the alternator. When the engine is off,
input energy from an on-site power supply or portable
generator (supplemented by solar panels) can be used to
rest or recharge the supply battery.
Exide Start AGM, Dual AGM and Equipment GEL
batteries are approved by DNV GL for safe and reliable
use at sea. This is the highest possible endorsement of
a marine market product. Very few lead-acid batteries
have passed the vigorous independent tests required
to attain this certification. It is an achievement Exide
Technologies is extremely proud of.
Page 30
Exide AGM or Premium
for high discharge of energy
to start engine
Exide Equipment GEL
for deep cycle – long, slow discharge
of electrical equipment
A similar concept applies to caravans without the need
for a starter battery and alternator input. In the case of
marine applications, the starter and supply batteries
follow the same general principle of the motorhome, but
there is an ever-increasing trend to prioritise navigation,
winching and communication, etc., which can be
absolutely critical, especially with sea-going vessels.
Larger boats have more on-board electric equipment
and generally operate on longer trips between battery
recharges. It is not uncommon on these vessels to find
a bank of supply batteries configured to provide ample
stored energy for the longest voyages.
DNV GL is an independent foundation
established in 1864 with the purpose
of safeguarding life, property and the
environment.
Find out more: www.dnvgl.com
All Exide leisure batteries are also
NCC verified and approved for use in
motorhomes and caravans.
Exide Technical Guide to Lead-Acid Batteries

Battery chargers for

workshops and end-users

Battery chargers are an essential tool for every

workshop, as well as for end-users who own seasonal
vehicles like vintage cars, motorhomes, caravans, boats
Exide future-proof chargers
or motorcycles. with specific modes for all flooded,
Apart from regions where cold-weather cranking is a AGM, EFB and GEL batteries
common issue, most car owners do not possess their
own charger. For owners of any vehicle that may remain
inactive for prolonged periods or those that incorporate
a supply battery application, a charger becomes a real
necessity. There are many occasions when a battery
benefits from a full charge, including just before you put
your vehicle into storage for an extended period of time.

In a typical workshop environment, there might be one

main workshop charger used for high-end luxury and
performance sports cars. This is often supplemented by
a number of portable chargers, for routine charging and
preservation of power input (Power Mode) when the
battery is disconnected for electrical work. Portability
is important when the car is moved out of the busy
workshop area after the service is complete.

Exide wants its customers to get the longest possible life

from their battery, so the company has launched a range
of chargers with optimised charging profiles. These have
individual modes for all battery types, including AGM, EFB
and GEL. Exide chargers are not limited to one battery
manufacturer, and cover all lead-acid batteries in the
automotive market.

Vintage vehicle owners and seasonal users are

more likely to need their own charger

Charging Tips
> Batteries should be charged off-vehicle if the voltage
drops below 12.45 volts (or 6.2 volts for 6V batteries)
> Use the specially developed Exide charger for best
results
> Avoid fire or flare and ensure good ventilation during
and after charging
> Allow the battery to rest for at least 12 hours after
charging

Page 31
Exide Technical Guide to Lead-Acid Batteries

A second century of innovation –

driving a better future

The Exide story started over 120 years ago, and the
company has been at the forefront of innovation
throughout its rich and fascinating history. As the
automotive industry evolved from novelty to main-
stream, it served drivers with easier, safer, bigger and
faster vehicles. At every stage, greater demand was put on
the battery, and Exide responded with constant product
improvements or by developing entirely new variants of
lead-acid batteries.
Today’s priorities are centred on higher levels of vehicle
automation, connectivity and greater fuel efficiency.
Exide has been making significant investments in these
areas, with large R&D initiatives underway at its state-of-
the-art research centres in Europe and the USA.
Exide is also taking part in research partnerships with car
manufacturers and scientific research consortiums. The
key focus points revolve around electronics, new alloys
and additives, improved separators, and cutting-edge
production processes. These are all essential aspects in
the company’s own testing and performance evaluations
of smarter battery management systems and advanced
battery technology.
Exide is developing the batteries that will power the
next generation of cars.

Page 32
Innovation
in action

Image: CC by Moshrunners
M5BAT Project
For the unique hybrid
5MW battery storage
project Exide is
pioneering technology
to improve energy
storage from renewable
PRT (Personal Rapid Transit) sources such as wind,
Exide Technologies helped the world’s first Personal water, solar and geothermal power. Funded by the
Rapid Transit System become a reality. Heathrow Pods German Federal Ministry for Economic Affairs and
are fully automated electric vehicles that transport up to Energy, this crucial project is at the forefront of the global
four people with luggage between London Heathrow’s quest to successfully balance power generation with
Terminal 5, various car park stations and a major hotel. consumption. Exide’s battery knowledge and experience
Passengers use a touch screen panel to call for the vehicle makes a valuable contribution to a greener world.
that usually arrives within 15 seconds and select their
destination for a non-stop trip at a maximum speed of
40kpm.
GNB
Each Pod employs a 7kW Synchronous AC drive motor
Sonnenschein
powered by a pack of 4 Exide 45Ah AGM Orbital batteries. Lithium
This battery combination meets the need for a high
Exide’s GNB Industrial
power draw over short periods time, low maintenance
Power division is
for continuous operation and the highest level of
making a strong
safety. Partial recharging takes place at every stopping
business case for
event when passengers board and disembark, and only
lithium battery power in 24/7 material handing. Forklift
occasionally during vehicle downtime is a full recharge
trucks and pallet moving is a huge part of the motive
required.
power sector. GNB have installed hundreds of new
Successfully operating since 2011, the Heathrow Pod lithium based systems since 2013, which yield substantial
system has delivered impressive results in reliability, cost and timesaving benefits. Sonnenschein Lithium’s
running costs and environmental benefits. This proven very fast recharge eliminates the requirement to switch
concepts is now the model for developments of new and battery packs and the need to maintain ventilated
even larger systems in the UK and Asia. battery charging stations.

Page 33
Exide Technical Guide to Lead-Acid Batteries

Battery business intelligence

Counter Staff Workshop End-user

Knowledge of battery technology Satisfaction
Information on Exide range +
Loyalty
Sales materials Workshop tools =
Used battery collection Increased sales

There are many battery suppliers on the market, but only Exide supports you in all these fields.
Exide is the best partner for your business, offering a broad range of products,
unmatched parc coverage and the most advanced technology available.

OE-quality products and Technical knowledge and sales

accessories from a trusted brand support material from a leader
in battery innovation

Training designed
around the needs of
your business
Excellent stock and
warranty management

Widest fitment range

and full marketing
support

Strong European logistics

Local customer
service

Exide local representatives

at your service
Page 34
Page 34
Lead-Acid battery stock management
and maintenance practices
Although today’s technology ensures that batteries have
a far longer shelf life than in the past, it is essential to take
great care in the handling and storage of these products so
that the battery is at its best when it reaches the customer.
Check the state of charge of your batteries
All batteries will slowly self-discharge over time, and it
is very important to regularly check the voltage and to
ensure that a charge is applied when the battery falls to
75% of its state of charge. Typically with a lead-acid battery
this occurs at 12.42V. If the voltage should drop below this
level, the battery will begin to sulphate.
Sulphation is a process which creates an oxidation layer
on the negative plate that will inhibit the current flow
and the battery will deteriorate. Recharging is important
as soon as this level of self-discharge is discovered, or the
capacity loss may be permanent.
Any battery that has dipped below 11.0V will have
developed sulphation that will not be remedied by
charging and so may not deliver the same performance
and working life to the customer who purchases this
product.
This check is also a good indicator of the age of stock
which should ideally be installed within 15 months of
the battery’s manufacture, and ensures that products are
always in a ready-to-sell state.
Voltage
State of Charge
The voltage indicates the state of charge. Recharge every battery at 12,42V or below!
Store batteries in the right way
Storing batteries need a specific approach, different than
storing other parts, because environmental conditions
affect the life time of each battery, although they are just
stored and not actually in use.
The most important two aspects should help to maintain
your battery inventory for both quality and shelf life.
Temperature
The main factor affecting the self-discharge of batteries is
the storage temperature. The higher the temperature, the
faster self-discharge will occur.
At the other end of the scale, the storage of batteries in a
colder environment, where temperatures drop below 0°C
should be avoided, as partially discharged batteries risk
freezing. This might cause permanent damage and the
product will fail or have its working life adversely affected.
Batteries discharge faster
at high temperatures
The recommended storage
temperature for batteries
is 20°C.
0 3 6 9 12
Time (months)
FIFO – First-In – First-Out
Definition of FIFO: A stock management method in which
batteries acquired first, are sold or installed first.
New stock should be placed at the back of the storage
rack so that older stock is used first. The delivery date for
each battery should be considered during checking of self-
discharge and the oldest stock should always be brought
to the front of the queue and used before any batteries
with a later delivery date.
If the stock management practices above are followed
with care, it should be easy to ensure that all product
stock is maintained in a ready-to-sell state and losses
through out of date or damaged products is kept to a
minimum. This also means that your customers will
be provided with batteries that solve their problems
straight away, and also gives a good, reliable working life
into the future.
Page 35
Exide Technical Guide to Lead-Acid Batteries

The end is just the begining

Did you know that the Lead-acid battery is the most

successfully recycled consumer product in the modern
world? In fact 95% of the battery can be reused. The
container can be crushed, processed into plastic pellets
to make new battery cases and lids. The valuable lead in
grids and terminals is smelted and re-formed to make new
grids and lead oxide. Even the electrolyte is neutralised
and chemically processed to extract the sulphuric acid.

There are universal regulations to stop scrap batteries

being disposed of in landfill, resulting in the release of
harmful chemicals that affect our environment. But with
increasing value of the raw materials, there is an economic
benefit beyond contributing to our social obligation.

Lead-Acid Batteries are the most

recycled consumer product

Lead-Acid battery components and LITHIUM BATTERIES

materials can be recycled again and again! Important Safety Notice
issued by Eurobat
DO NOT send lithium batteries
to lead recyclers
Use an approved facility for
treatment and recycling.

Plastic Lead Electrolyte There is a serious RISK OF

crushed and grids/terminals neutralised and FIRE and EXPLOSIONS if
processed into smelted and cast chemically
plastic pellets as lead ingots processed lithium batteries enter the
lead battery collection and
recycling process

Batteries can appear similar

so make sure lead and lithium
batteries are IDENTIFIED and
SORTED

New cases New grids & Neutralise Tips to identify battery types
and lids lead oxide or re-used Read the label - Look out for the
manufactured from produced from the clear water and Pb symbol on lead batteries or the
recycled pellets recycled material new electrolyte Li symbol on lithium batteries. You may
also be able to identify them by their
manufacturer.

Notice the weight difference - Although

they have similar dimensions lithium
are much lighter than lead batteries.

Page 36
Terminology guide
Absorbed glass mat (AGM)
Type of lead-acid battery in which the
electrolyte is absorbed into a fibreglass
mat. The plates in an AGM Battery may
be flat or, more exceptionally, wound in a
tight spiral. In cylindrical AGMs, the plates
are thin and wound, like most consumer
disposable and rechargeable cells,
into spirals so they are also sometimes
referred to as spiral wound.
Ampere, or Amp
The unit of measurement of current
flow. One volt placed across a one ohm
resistance will cause a current of one Amp
to flow. One amp for one hour is called an
“amp-hour” or AH.
Ampere-hour or Ah
The unit of electrical capacity - this tells
you how much energy the battery will
store. Current multiplied by time in hours
equals ampere-hours. A current of one
amp for one hour would be one amp-
hour; a current of 3 amps for 5 hours
would be 15 Ah.
Battery
A battery is an electric device that
converts chemical energy into electrical
energy, consisting of a group of electric
cells that are connected to act as a source
of direct current. Batteries are made of
connected cells encased in a container
and fitted with terminals to provide a
source of direct electric current at a given
voltage. A battery is characterised by its
chemical composition (combination of
metal(s) and electrolyte used), voltage,
size, terminal arrangements, capacity
and rate of capability or more cells.
Battery pack (bank)
Set of any number of (preferably) identical
batteries or individual battery cells. They
may be configured in a series, parallel or
a mixture of both to deliver the desired
voltage, capacity, or power density.
Cell
Basic functional unit providing a source
of electrical energy by direct conversion
of chemical energy. A cell consists of
two dissimilar substances, a positive electrode; similarly, the negative plates
electrode and a negative electrode, form the negative electrode.
that conduct electricity, and a third
In the process of charging, the cell
substance, an electrolyte, that acts
is made to operate in reverse of its
chemically on the electrodes. The two
discharging operation; i.e., current is
electrodes are connected by an external
forced through the cell in the opposite
circuit. The electrolyte functions as an
direction, causing the reverse of the
ionic conductor for the transfer of the
chemical reaction that ordinarily takes
electrons between the electrodes.
place during discharge, so that electrical
Cycle energy is converted into stored chemical
energy.
A “cycle” is a somewhat arbitrary
term used to describe the process of Valve-regulated sealed battery
discharging a fully charged battery
Battery in which cells are closed but
down to a particular state of discharge.
have an arrangement (valve) which
The term “deep cycle” refers to batteries
allows the escape of gas if the internal
in which the cycle is from full charge to
pressure exceeds a predetermined value.
80% discharge. A cycle for an automotive
battery is about 5%, and for telephone Vented cell
batteries is usually 10%.
Cell with a cover having an opening
Electrolyte through which products of electrolysis
and evaporation are allowed to escape
Conductive chemical (such as acid),
freely from the cell, in order to avoid
usually liquid, solid or gel, in which the
excessive pressure inside the cell.
flow of electricity takes place within the
battery, and which supports the chemical Vent valve
reactions required.
Part of certain types of batteries which
Lead-acid battery permits the escape of gas in the case of
excess internal pressure but which does
Lead-acid batteries are the most
not allow the entry of air
commonly used rechargeable auto-
motive batteries today. Their power-to- Volt (V)
weight ratio is often quite good. Also,
The unit of measurement of electrical
the energy-to-volume ratio is good
potential or “pressure”. Most batteries
compared to other types of batteries.
come in 6, 12, & 24 volt. A single cell is 2
They are cheap and can supply high
volts.
surge currents needed to start engines.
Every car uses a lead-acid battery for this Watt (W)
purpose.
A unit of power. 1W is 1 Joule per second
Separator (J/s), or also 1 amp multiplied by 1 volts
(AxV). 1 amp at 120 volts gives the same
Material with an ion permeable structure
result in watts as 10 amps at 12 volts.
that provides electrical insulation
between plates of opposite polarity in Watt-hour (Wh)
a cell
Watt-hours measure amounts of energy
Storage battery for a specific period of time. For example
if a 60 W light bulb is on for one hour,
A storage battery consists of several
then that light bulb will have used 60 Wh
cells connected to each other. Each
of energy. If left on for two hours, then
cell contains a number of alternately
the 60 W light bulb will have used 120Wh
positive and negative plates, a separator
of energy.
and electrolyte. The positive plates of the
cell are connected to form the positive
Page 37
 The power of
Exide’s Brands

Exide has a number of national and international brands.

These are instantly recognised in local markets, with a
reputation for quality and performance. It makes good
commercial sense to build upon names that are respected
and trusted. Confidence in quality is a very decisive factor
in influencing choice.

The power of brands can never be underestimated. From

trade counter shelves to the quality of components fitted
in customers’ cars, people feel more certain of a product
that is instantly identifiable.

Keeping the Exide Brand in front of millions of motorsport fans across Europe

Page 38
Exide Technical Guide to Lead-Acid Batteries

Exide OE – Trusted by leading

vehicle manufacturers

Light Vehicles Commercial Vehicles Motorbike Marine & Leisure

Car Delivery Long-Haul Construction Agriculture Passenger Bike Boat Motorhome

Truck Truck Bus & Coach

Alfa Romeo Maserati Isuzu AGCO Evobus BMW Azimut Carthago

Audi Mercedes- Iveco Argo Tractors Iveco Bavaria Reisemobile
BMW Benz MAN Bobcat MAN Beneteau CS-Reisemobile
Mini Fendt Caravan
Chrysler Nissan Case New Holland Scania Catana
Nissan Hymer AG
Citroën Piaggio Claas Solaris Dufour
Dacia Peugeot Renault-Volvo John Deere Jeanneau
Fiat Renault Scania Komatsu San Lorenzo
Ford Saab Kubota Sessa
Hyundai Seat Manitou Marine
Infiniti Skoda Ravo Wauquiez
Jaguar Suzuki Same Deutz Fahr Exide is also
Kia Toyota Terberg the selected
Lancia Volkswagen Terex brand of many
Volvo European city
Land Rover Wacker Neuson transport
Mazda Wirtgen Group operators

There has never been such a wide choice of the largest network of European sales offices,
parts available in the aftermarket. This creates with knowledgeable people providing local
challenges for workshops, which must take support. When you see Exide on the label, you
into account the best product for a particular can be confident that the battery was
model of car, as well as the individual manufactured to the highest
needs of each motorist. In the standards, on the same
battery market, Exide has production lines as the
managed to simplify this company’s OE batteries.
complexity, and present our
Exide is committed to helping
partners with clear quality
you succeed in the
ranges and meticulous
aftermarket. We provide
fitment guides.
quality training and excellent
All our products are technical support, helping
designed to the correct you to understand the
specification and offer unique function and
the performance expect- performance benefits of
ed by vehicle manufact- every kind of lead-acid
urers. We have some of battery. This lets you make
the most advanced more informed decisions
technology in the industry, a and offer better
reputation for offering professional recommend-
industry-leading products, and ations to your customers.

Page 39
Exide Technical Guide to Lead-Acid Batteries

Aftermarket facts and figures

European vehicle parc and seasonal battery sales
Light Vehicle Parc Commercial Vehicle Parc Motorcycle/Moped Parc Motorhome/Caravan Parc

‚000 units ‚000 units ‚000 units ‚000 units

1 Germany 44,403 1 France 6,608 1 Italy 8,505 1 Germany 1,340

2 Italy 37,081 2 Spain 5,085 2 Germany 5,888 2 France 1,281

3 France 31,800 3 Italy 4,179 3 Spain 5,033 3 United Kingdom 765

4 United Kingdom 30,557 4 United Kingdom 4,179 4 France 3,015 4 Netherlands 547

5 Spain 22,030 5 Poland 3,447 5 Greece 1,802 5 Sweden 361

6 Poland 20,004 6 Germany 2,967 6 United Kingdom 1,328 6 Spain 360

7 Netherlands 7,979 7 Greece 1,349 7 Poland 1,311 7 Italy 266

8 Belgium 5,573 8 Portugal 1,252 8 Netherlands 1,228 8 Denmark 157

9 Greece 5,108 9 Netherlands 958 9 Czech Republic 1,016 9 Finland 120

10 Romania 4,908 10 Romania 851 10 Switzerland 852 10 Belgium 90

11 Czech Republic 4,833 11 Belgium 831 11 Austria 755 11 Norway 86

12 Austria 4,695 12 Czech Republic 636 12 Belgium 646 12 Switzerland 71

13 Sweden 4,585 13 Sweden 595 13 Finland 564 13 Austria 55

14 Portugal 4,496 14 Norway 568 14 Portugal 509 14 Portugal 27

15 Switzerland 4,384 15 Finland 559 15 Sweden 363 15 Slovenia 16

Others 12,606 Others 3,664 Others 1,420 Others 55

Total 269,537 Total 37,726 Total 34,235 Total 5,597

TOTAL EU28 +
Iceland, Norway
& Switzerland
270m
TOTAL EU28 +
Iceland, Norway
& Switzerland
38m TOTAL EU28 +
Iceland, Norway
& Switzerland
34m TOTAL EU28 +
Iceland, Norway
& Switzerland
5.5m
Other significant markets Other significant markets Other significant markets

Russia 37,420 Russia 6,609 Russia 2,497

Turkey 9,284 Turkey 4,331 Turkey 2,658

Ukraine 7,347 Ukraine 1,886

Source: Source: Sources: Source:

Eurosat (2014) and International Organisation of Eurosat (2014) and International Organisation of Association of European Motorcycle Manufacturers European Caravan Federation (ECF) 2015
Motor Vehicle Manufacturers (OICA) Motor Vehicle Manufacturers (OICA) (ACEM ) 2014 and Russian police statistics

Light Vehicle Commercial Vehicle Motorcycle and Powersport Motorhome/Caravan

Seasonal Battery Sales Seasonal Battery Sales Seasonal Battery Sales Seasonal Battery Sales

JAN JAN JAN JAN

FEB FEB FEB FEB
MAR MAR MAR MAR
APR APR APR APR
MAY MAY MAY MAY
JUN JUN JUN JUN
JUL JUL JUL JUL
AUG AUG AUG AUG
SEP SEP SEP SEP
OCT OCT OCT OCT
NOV NOV NOV NOV
DEC DEC DEC DEC

Peak sales period: Peak sales period: Peak sales period: Peak sales period:
September to February October to March January to June February to July

Page 40
 Battery replacement cycle
Boat Parc LV & CV Battery Replacement Cycle LV Average Battery Life by Country

1 2 3 4 5 6 7 8 9 10 Years

Italy 4.5
100%
‚000 units 100% 100%
98% Poland 5.0
1 Sweden 781 91%
Turkey 6.0
2 Norway 758
78% Austria 6.3
3 Finland 710 75%
4 Italy 510 Belgium/Luxembourg 6.3
65%
5 United Kingdom 500
Cyprus 6.3
56%
6 France 485
50% Czech Republic 6.3
7 Netherlands 408

8 Germany 404 Denmark 6.3

9 Denmark 310 33% Estonia 6.3

10 Spain 174 25%
Finland 6.3
20%
11 Greece 135
15% France 6.3
12 Croatia 104

13 Switzerland 85 1% 5% Germany 6.3

0%
0%
14 Austria 65 Years... 1 2 3 4 5 6 7 8 9 10 > Hungary 6.3
15 Poland 35
Latvia 6.3
Others 196
Lithuania 6.3
Total 5,660 Key points of battery replacement cycle:
Malta 6.3
TOTAL EU28 +
Iceland, Norway
& Switzerland
5.7m Light vehicles’ replacement cycle Netherlands 6.3

(average 1 battery per vehicle) Norway 6.3

Other significant markets
> Minimal battery replacement in the first three years Romania 6.3
Turkey 72 > More than 50% of batteries replaced by the sixth year
Slovakia 6.3
Russia 30 > 100% of batteries replaced within ten years
Ukraine 15 Slovenia 6.3

Source:
Heavy vehicles’ replacement cycle Sweden 6.3
International Boat Industry (IBI) 2015

(average 1.7 batteries per vehicle) Switzerland 6.3

Boat > 20% of batteries replaced within the first year European Average 6.5
Seasonal Battery Sales > 65% of batteries replaced within the second year
Greece 7.0
JAN
> 100% of batteries replaced within three years
FEB Portugal 7.0
MAR
APR
Heavy vehicle batteries (for vehicles of more than 3.5 Spain 7.3
MAY tonnes) have a shorter battery life-cycle due to their
JUN higher utilisation and annual average mileage and their Iceland 8.4
JUL
higher energy requirements caused by their greater
AUG United Kingdom & Ireland 9.0
SEP
weight and usage.
OCT
NOV Factors that influence battery replacement rate
DEC include vehicle parc age, on-board electrical
Source: equipment, climate conditions and service frequency.
Peak sales period: Eurobat Study This differs from country to country as shown in
February to July (The availability of automotive lead-based batteries for recycling in the EU) the list above based on Exide estimates.

Page 41
Apps and mobile product information

Exide Battery Finder App Mobile Website: www.exide.info

Search by car model, VIN or registration number
to find the correct battery fast.
Exide battery catalogue powered by TecDoc in
your pocket!
Scan the QR code or type in a simple URL to
instantly access product information, user
guides, manufacturing information and local
contacts.

FREE download for iPhone & Android Available on any internet-connected device

Regularly updated fitment lists for many makes

and models of cars, vans, trucks & bikes.

www.exide.info • www.tudorbatt.info • www.fulmen.info • www.centra.info • www.deta.info • www.sonnak.info

Page 42
Exide Technical Guide to Lead-Acid Batteries

New standards for on-shelf

and online communication
> New logical label design
> Emphasis on clear information to make the right battery choice
> Huge improvement for stock handling and retail selection by the end consumer

77
760

Dimension Graphic Larger Part Number

Visually easier to grasp For easier shelf selection
and check

Clear Benefit Icons Electrical Performances

Greater assurance for end consumer Large print for positive verification

77
760

Original-Equipment Manufacturer Simple URL Individual QR code

Indicator of proven quality Easier to remember and quick to type Smartphone access by simply
for individual product information scanning the code

Page 43
Exide Technical Guide to Lead-Acid Batteries

Exide Battery Range

Light Vehicles

Start-Stop Start-Stop

Start-Stop AGM Start-Stop Auxiliary

Absorbent Glass Mat Absorbent Glass Mat
Ideal for large cars, SUVs, Power of electrical
vans and vehicles with equipment in certain cars, as
Start-Stop and power-hungry a complement to the main
electrical equipment starter battery

x4
Conventional
Performance Very high
Other AGM
Premium
The high-performance
battery with Carbon Boost
120%

Standard
conventional
battery
Power Cycle Charge
Life Acceptance

SUPER FAST
RECHARGE

Start-Stop EFB
Premium Carbon Boost has improved charge acceptance and
Enhanced Flooded Battery recharges up to 1.5 times faster than standard batteries.
Ideal for small to mid-sized While battery failure remains the number one cause of car
cars with Start-Stop breakdowns, fast recharging considerably reduces the risk of
and other fuel-saving breakdowns by helping the battery retain a healthy state of
charge for longer.
features

x3
Performance High

Other EFB

110%

Standard
Excell Classic
conventional
battery The reference battery The economy
Power Cycle Charge with a range covering solution for older cars
Life Acceptance 99% of the car parc with basic equipment

Page 44
Commercial Vehicles

High Vibration Resistant Conventional

StrongPRO PowerPRO
New-generation HVR® (high vibration resistance) Superior cranking power with more plates and active
design with Carbon BoostTM material to maximize grid surface

›› Extremely robust – latest HVR® technology

›› Mandatory for chassis-end installation (e.g. Euro 5/
Euro 6 trucks) and ideal for rough terrain
›› Carbon BoostTM for faster recharge and reduced acid
stratification
›› Ideal for long-haul trucks with comfort equipment
to support “life on board”
›› Maximum starting reliability after overnight stay
StartPRO
›› OE experience inside
Complete range covering almost 100% of vehicle parc,
›› First class safety features
including special types
›› Maintenance free – no topping up
›› Optimal total cost of ownership (TCO)

Conventional

PowerPRO Agri & Construction

Designed specifically to fulfil the demanding
requirements of major agriculture and construction
OEMs, PowerPRO Agri & Construction offers
EndurancePRO outstanding reliability, starting power and
high capacity.
50% more cycle life compared to standard truck
battery due to advanced SHD technology with glass
mat separators

Page 45
Exide Technical Guide to Lead-Acid Batteries

Exide Battery Range

Motorbike & Sport

Exide Bike

GEL AGM Ready AGM Conventional

Superior capacity
Superior power Superior power
Maximum safety
Ultra safe features Great safety features Good power
Performance Maximum cycle life
Extended cycle life Extended cycle life Good cycle life
Highly vibration resistant
Highly vibration resistant Vibration resistant
Deep-discharge protection

Ideal for premium

Recommended Ideal for high-class Suitable for standard
vehicles with built-in Fits most applications
motorcycles, powersport power needs
vehicle parc or add-on electrical
and off-road vehicles
equipment

Recommended
applications

Could require
Maintenance water refilling
MAINTENANCE FREE MAINTENANCE FREE MAINTENANCE FREE

Side mounting
Upright mounting only
approved HIGH INCLINATION HIGH INCLINATION MEDIUM INCLINATION

*
Hermetic seal
HERMETIC SEAL HERMETIC SEAL HERMETIC SEAL

Initial filling Initial filling

Ready to use required required
READY TO USE READY TO USE

Acid pack
No initial filling No initial filling
included ACID PACK INCLUDED ACID PACK INCLUDED

Technology Gel AGM charged AGM dry charged Flooded dry charged

* Becomes sealed after initial filling

Motorbike & Sport Li-ion
Ultra-lightweight design reduces the overall weight of a bike,
enabling faster acceleration and better performance.

Page 46
Marine & Leisure

Engine Start Equipment Supply

Start Start AGM Equipment Equipment GEL

Low maintenance battery Maintenance free battery Low maintenance battery Maintenance free battery
for installation in special with high vibration and for installation in special with high vibration and
container tilt resistance plus up to container tilt resistance plus up to
50% faster recharge 50% faster recharge

Up to 90% recommended
depth of discharge

Smallest volume/weight
ratio for Wh supplied

Start & Supply

Exide Start AGM, Dual AGM and Equipment GEL

Dual
Low maintenance battery
for installation in special
container
batteries are approved by DNV-GL for safe and reliable
use at sea. This is the highest possible endorsement of
a marine market product. Very few lead-acid batteries
have passed the vigorous independent tests required
Dual AGM to attain this certification. It is an achievement Exide
Technologies is extremely proud of.
Maintenance free battery
with high vibration and
tilt resistance plus up to
50% faster recharge

DNV-GL is an independent
foundation established in
1864 with the purpose of
safeguarding life, property
and the environment

Page 47
Exide Technologies, with operations in more than 80 countries and more than 120 years of experience, is one of the world’s
largest producers and recyclers of lead-acid batteries. The company develops state-of-the-art energy storage solutions for the
automotive and industrial market. Leading car, truck and lift truck manufacturers trust in Exide Technologies as an original
equipment supplier. Exide also serves the aftermarket through a portfolio of successful and well-known brands.

Exide Transportation manufactures batteries for light and commercial vehicles, as well as agricultural and marine leisure
applications. Industrial markets – under the division GNB Industrial Power – include efficient energy storage solutions for
motive power applications such as lift trucks, cleaning machines and other commercial electrical vehicles, and network power
applications such as telecommunications systems, renewables, and uninterruptible power supply (UPS).

Exide’s engineers have always been at the forefront of bringing important innovations to the industry. Exide’s ISO/TS-certified
manufacturing facilities ensure that customers receive products that are produced with maximum efficiency and fulfil the
highest quality standards, while minimising impact on the environment.

Exide’s extensive sales and distribution network provides quality service and delivers on time to its customers. Its world-class
recycling facilities ensure that batteries will be reused, helping to make a positive contribution to the environment. Exide also
provides services, accessories and energy consulting to its clients.

Starting Power Motive & Network Power

Research, Production Sales & Consulting Service Recycling

Development & Engineering

Disclaimer
Exide Technologies and its content suppliers make no representations or warranties about the information, content, materials, or products included in this publication. This publication and all content are
provided “as is” without warranties of any kind, express or implied. To the full extent permissible by applicable law, Exide Technologies and its content suppliers disclaim all warranties and conditions with regard
to this information, including all implied warranties and conditions of merchantability, fitness for a particular purpose, and non-infringement. In no event shall Exide Technologies or its content suppliers be liable
for any special, indirect or consequential damages or any damages whatsoever resulting from loss of use, loss of data or loss of revenues or profits, whether in an action of contract, negligence or otherwise, arising
out of or in connection with the content available from this publication. Users are advised that content may include technical inaccuracies or typographical errors. Exide Technologies or its content suppliers may
make improvements or changes in the site, content, or in any of the products and services described on the site, at any time and without advance notice.

Copyright
All content included in this publication, such as text, data, product information, graphics, logos, images and button icons, is the property of Exide Technologies or its content suppliers and protected by international
copyright laws. The content of this publication, including the reproduction, modification, distribution, transmission, republication, display or performance of the content on this site is strictly prohibited.

Trademarks
Exide®, Tudor®, Fulmen®, Centra®, Deta® and Sonnak® are all trading titles and trademarks owned by Exide Technologies.

European Headquarters
Exide Technologies SAS
5 allée des Pierres Mayettes,
92636 Gennevilliers
France

Tel: +33 1 41 21 23 00

Fax +33 1 41 21 27 15 Developing more successful

www.exide.com partnerships with the aftermarket
Page 48