BACK TO INDEX PRODUCT SUPPORT CONTACT US WHAT’S NEW For over a decade, the Water Injector™ system has been the world’s fastest, and most reliable way to add water to industrial batteries. It is very simple to use: an operator clicks on a water-hose, opens a valve, and in 15 seconds or less the entire battery is watered - perfectly. Even experienced battery users are astonished at the speed of filling. The system saves money in two ways. First, it cuts labor costs, often paying for itself within its first year of operation. Second, it extends the life of each expensive battery it is installed on due to improved quality of watering. The system also improves safety and environmental cleanliness. There is no need to peer into cells to inspect levels as with manual filling, and Water Injectors™ automatically fill each cell to the correct level, so no overfilling and no electrolyte overflow during charge. The Injector system is outstandingly durable. Designed for harsh industrial environments, it will shrug off abuse that would destroy most other systems, and continue to work dependably for the life of the battery. In the long run, they have the best financial ROI of all available filling systems. See for yourself with our ROI Calculator. This is especially true in heavy-duty applications where breakage of more fragile systems become costly. It is also true in the new and growing watering service market where battery watering is outsourced to specialists. INJECTOR SYSTEM OPTIONS Injectors can be ordered in one of two ways:  1. Instant-InstallTM  Fully assembled, Custom Fit 2. Semi-assembled Flexible Fit, Easy to Install Instant Install option Instant-Install is a fully assembled system – revolutionary in the battery industry. The entire Injector “string” is assembled in our factory, complete in every detail, matched to and ready to click on to a specific battery type. It can be installed on a battery completely in about 3 minutes, by unskilled labor. Installation can occur either in a battery factory at production time or in an application, simply by snapping the Injectors into the cells. Instant-Install is most valuable where multiple, identical batteries are to be fitted with Injectors. Consider the time saved if several hundred batteries are to be fitted. This is the case in many large warehouses and distribution centers, and the Instant-install option is now so popular in the USA market that most of the Injector systems currently delivered to customers are Instant Install.  Another benefit of Instant Install is that there is only one part number for the entire assembly, simplifying the customer’s purchasing and inventory control procedures. The tubing is continuous, with holes punched at the injector locations. Twin seals prevent water leakage from the tubing even at high pressure; in fact, the higher the pressure, the better the seal. This exclusive construction has been proven in the toughest applications for over a decade; it has simply eliminated tubing blowing off under pressure. Semi-assembled option The Semi-assembled option is similar to Instant Install, however holes in the tubing do not come already punched and ready to fit to a particular battery type. Instead the installer must punch holes in the tubing to fit each system (punch tool available).  This Semi-Assembled option is more flexible than Instant Install because it can be used on any battery with the correct, or fewer, number of cells. It is most useful where there are a variety of battery types to convert in the field. We provide battery layout guides for installers to use. The installer snaps the string of Injectors on to the battery, sliding each Injector along the tubing until the layout is perfect. He then marks the tubing with a pen, moves each Injector aside, punches a hole (actually a pair of holes), and then returns the injector to its marked location. He then trims any excess tubing, attaches the end Injector and that’s it.  Features and benefits Very fast operation:  An average industrial truck battery can be filled, with precise level control, in less than 15 seconds. Yet the system is gentle. The secret is parallel filling, made possible by the unique low-friction tubing and pressurized water supply. Compact: A very low profile allows them to fit on almost any battery. Injectors can snap in and out to allow inspection of electrolyte levels and specific gravities. Rugged: Tough enough to survive impacts, abuse and extremes of battery temperatures. There are no exposed parts to break off even when an Injector is removed from a cell. True level sensing mechanism. Needs no submergence to sense level as a float does. Can work right down to the top of the separators.  Will not fail if it touches cell components. No-freeze tubing: The surplus water drains from the tubing into cells after filling is complete. This allows the system to be used in cold stores and other freezing environments. 2-Stage Filtration: In addition to the filter screen in the water tubing, each Injector has its own individual filter. 5 Year warranty: Philadelphia Scientific warrants its Water Injectors against defects in materials and workmanship for a period of 5 years from the date of sale by Philadelphia Scientific. Single part number: (Instant-Install type  and Semi-Assembled only). The entire Injector system is pre-assembled on to a single length of flexible plastic tubing - with all fittings and accessories attached. Each assembly has a single part number to simplify inventory control. Exclusive product: The Water InjectorTM system is manufactured by Philadelphia Scientific. For well over a decade, it has been the fastest, most reliable battery filling system in the world. Exclusive reconditioning service: Injectors are so tough that we can recondition used ones. We discard the old tubing, clean the injectors in a special washing machine and, after a 100% inspection, install them on a new length of tubing. That means even more savings for our customers. How water injectors work Inside each Water Injector is a precision level-sensing valve enclosed in a strong protective housing. When the electrolyte level rises to reach the tip of the Injector, the valve shuts off instantly. There are no exposed parts to stick or break and individual Injectors are strong enough to survive the abuse of tough applications. There are no floats of any kind involved because this is not a hydrostatic system. It is a hydrodynamic system powered by the incoming pressurized water. One great  benefit of this approach is that the actuating (shutoff) force of an Injector is typically 20 times stronger than the buoyancy available with a float. This makes Injectors virtually immune to “sticking” due to gummy residues in the cells. It is what gives them their legendary reliability. The other enormous benefit of pressurized water is that it produces fast filling – which translates into productivity gains and cost savings. Furthermore, a short, 15 second fill cycle also raises operator confidence because he or she can be present and attentive during the entire filling operation. That is not possible with systems that take minutes to fill. To achieve their superior speed and reliability, Water Injectors must be supplied with  adequate water pressure. However, this is not a difficult requirement to meet. (See the link below on water supplies). For installations with only one or two batteries, we recommend our Watering Gun, our Float Valve, or a contract Watering Service.   Injectors are usually installed on a battery in series. That is, the water tubing forms a single continuous, serpentine flow path on top of the battery.  Only occasionally are there “Y” type connectors required. The water tubing itself has a large bore to minimize pressure drop. The system connects to a normal water hose with a garden-hose style quick-connect coupling. A spinning flow indicator stops when the battery is full. After filling, excess water in the tubing drains into the cells to prevent freezing in cold store applications.   Custom systems Various custom versions of Water Injectors have also been developed for specialized applications, as follows. Example 1: The most powerful battery in the world, the 5,000 volt,  27 megawatt Battery Energy Storage System (BESS) in Fairbanks, Alaska, built by ABB and SAFT,  has 15,000 nickel cadmium cells that are filled by special Water Injectors. PS also designed and supplied the web-based remote monitoring system for this project – probably the most sophisticated battery monitoring system ever built. Visit the BESS page for more information. Example 2: The advanced German ICE high-speed train is equipped with lead-acid lighting batteries. Water Injectors are approved for watering these batteries. Visit the Transportation Applications page, for more information.   water supply systems Because Water Injectors™ are the fastest battery filling system in the world, they require a high flow rate and adequate water pressure. We have developed a wide variety of world-class water supplies to provide the ideal fit for every application. Direct fill from taps or faucets is also acceptable if the pressure and flow rate is adequate (Qualify your water source with a Flow-checker). Check out our factory authorized Injector water supplies.