Common Battery Warranty Claims That Can be Prevented

February 2026

I doubt Gaston Planté, the French physicist who discovered the lead-acid battery in 1859, could envision how great an impact his invention would have for modern man. The lead-acid battery was the first rechargeable electric battery marketed for commercial use.

When Meggitt’s Securaplane brand introduced its SLA (sealed lead-acid) battery for use in aviation, it had a significant impact on the reliability and performance expectations of aircraft batteries with the potential for longer service life and less maintenance costs.

Securaplane products have a limited 30-month warranty on main ship battery covering workmanship. Sulfation of the plates and damaged terminal studs are common warranty claims that can be prevented or lessened by following simple operational and maintenance procedures.

Battery Sulfation

Sulfation is the formation of lead sulfate on a battery’s plates. It occurs when a battery is not allowed to come to a full charge before operation or is left idle for long periods of time. If sulfation is allowed to form and grow unchecked, it will inhibit the flow of electrons and ultimately lead to premature battery failure.

Preventing Sulfation

Allow the battery to become fully charged before the next engine start.
Do not shut the engine down before the battery is completely charged.
Do not leave the battery idle for long periods of time to slowly discharge.
Allow the battery to fully recharge overnight on a tickle charger

Damaged Terminal Stud

When reblocking the battery or replacing cell packs, it is quite easy to unintentionally over torque and twist off the terminal studs. As per the CMM (component maintenance manual), use only a calibrated torque wrench.

If a warranty is claimed, Meggitt Securaplane may request the battery or cell packs to be returned for further analysis. This analysis will determine the health of the plates and, in the case of a twisted stud, the condition of the stud's spot weld to the connector bar. Don’t discard the battery or cell packs until the warranty issue has been resolved.

Battery Service Live Extension

Meggitt Securaplane has released a Battery Service Life Extension procedure (SL-9750W03X0-24-121, Rev. 2, date 10/16/12). It is a low-current discharge/recharge cycle that could extend the useful life of your Securaplane main ship battery. Please contact me for more information.