Originally Posted By: Tosh
I read here on BITOG years ago that adding new electrolyte rather than distilled water causes it to become too concentrated (not a good thing), as it's mainly water that evaporates and needs replacing.
I only buy batteries that have removable caps, and check the level about once a year.
Battery acid can be added, but only so much as to bring up the final electrolyte solution to 1280 specific gravity. Most battery manufacturers recommend adding water only for safety reasons. Should you spill water across cells at the top nothing will happen as distilled water does not conduct electricity, should you spill acid across cells consider yourself lucky that the battery won’t short and blow up in your face as electrolyte conducts electricity.
Adding too much acid, over 1280 will cause excessive gassing and excessive sulfation as there is too much molecular action inside the battery, a natural process the battery uses to bring itself back to equilibrium. This in term damages the plates, separators which increases resistance and reduces the battery’s effectiveness to produce high starting currents. To be able to add the correct amount of acid, you have to use a temperature compensated hydrometer and can be done safely as long as you know what you are doing.
Adding water has another hidden meaning, checking the battery for overcharging. Should your water evaporate rapidly requiring frequent refills your battery is telling you that it is being overcharged as it rids itself of excess energy by breaking water into hydrogen and oxygen. Adding too much water only reduces the specific gravity and increases internal resistance by a small factor, not as much as overfilling with acid causing premature sulfation and permanent damage.