Since 1977

HBL Power Systems Ltd. Welcomes you all

Since 1977

Our Service Policy

We dont forget our batteries after you have paid for them.

We achieve this through National Service Network with dedicated customer centric teams Well equipped centers even at remote locations Time bound empathetic complaint disposal. Reliable and cost effective service solutions Imparting customer training

Since 1977

Expertise in Battery Technologies

Since 1977

Nickel Cadmium (1.2 V) Sintered Plate ---- Vented & Sealed Pocket Plate ---- Vented & Valve Regulated Fibre Plate
Silver Zinc (1.5 V) Primary & secondary Lead Acid (2 V) Valve Regulated Lead Acid (VRLA) Valve Regulated Lead Acid GEL Pure Lead-Tin Monoblock (SMF) Tubular Lead Acid (LMLA) Tubular Lead Acid GEL Lithium (3.5 V) Lithium Thionyl & Chloride
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Battery Basics

What is cell or battery?

Cell is a device that converts the chemical energy into electrical energy by means of an electrochemical reaction. Battery consists of two or more cells electrically connected.
In common usage, the terms "battery" and "cell" are used interchangeably.

Types of Batteries
Battery

Primary (Use and throw)

Secondary (Rechargeable) . Acid .

Alkaline

Battery Capacity:
Amount of charge available - ampere-hours (Ah).

Depends on
1. 2. 3.

Quantity of active materials Amount of electrolyte Surface area of the plates

Measurement:
Terminal voltage under discharge at standard conditions of 27C

Rated capacity: Amount of charge available in ampere-hours (Ah) when battery discharged at specified rate. Example: Lead-acid battery rated for 200 Ah (for a 10-hour rate) will deliver 20 amperes of current for 10 hours under standard temperature conditions before its terminal voltage reaches specified value. Battery capacity varies with the discharge rate.

Battery connections
Series Connection
Positive terminal connected to the negative terminal increases the overall voltage but the overall capacity remains the same.

Parallel Connection
Like terminals connected together, the overall voltage remains same but capacity will be increased

LEAD ACID BATTERY TECHNOLOGY

HBL POWER SYSTEMS LTD

Classifications of Secondary Lead Acid Batteries

Lead Acid batteries

Flooded Tubular Flat plate Tubular Gel Lead Calcium Tin Pure Lead Tin AGM VRLA Flat plate Gel Lead Calcium Lead Calcium Tin

Since 1977

Components of Lead Acid Battery / Cell

Since 1977

Evolution of MF-Lead Acid Battery

Conventional
Early M F (LM)
Maintenance Free (Low Maintenance) +

Maintenance Required
+

Valve Regulated with Absorbed Electrolyte

Maintenance Free +

PbO 2

Pb PbO 2 Pb PbO 2 Pb

Vented Small Acid above the Plates Sediments Bridge at the bottom

Vented
- Large Free Acid - above the Plates - Envelope Separators

Acid Starved Immobilized Acid Smaller Size

Absorbed Electrolyte in Separator ( AGM)

(No Shedding) Tubular Positive Plate

Different types of Plates

Plante

Flat grid

Tubular

Plate/Electrode

Active material Grid

Stores the charge - Electrical conductor & support for active material

Different types of plates

Plante plate

: Active material has been electrochemically

produced over lead sheet

Flat pasted plate : Active material has been supported by

lead alloy mesh
Poor cyclic life - Better high rate

Tubular plate

: The paste is held in micro-porous, non-

conductive tubes (gauntlets)

- Better for heavy cycling

Since 1977

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Alloys
Battery grid is made from a lead alloy Alloying elements
Antimony Calcium Tin Selenium Lead antimony alloy Lead calcium alloy Lead tin alloy Low antimony alloy reduced water loss

Tin is added to lead-calcium positive grids to improve the i) cycle life ii) less corrosion Pure lead is very soft

Antimony Vs Calcium
1. Better deep cyclability with antimony 2. More gassing with antimony more water consumption 3. Low self discharge with calcium low float current 4. Positive plate growth with calcium due to grain boundary corrosion buckling / container rupture

Since 1977

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Since 1977

VRLA Design

Absorbed electrolyte Special alloys - minimizes gassing Gas Recombination Principle Valve Regulated High purity metals
Separato r +Ve Plate -Ve Plate

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Conceptual View - Oxygen Recombination Process

The reactions involved in the cell: At the negative electrode Discharge Pb + H2SO4 Charge At the positive electrode Discharge PbO2 + 2H+ + H2SO4 +2eCharge PbSO4 + 2 H2O E = 1.685V PbSO4 +2H+ + 2eE = 0.356V

Overall Reaction: Discharge PbO2 + Pb + 2 H2SO4 Charge E = 2.041V PbSO4 (+ve Plate) + PbSO4 (-ve Plate) + 2 H2O

Acid Specific Gravity

Specific gravity of acid is the measure of its concentration
Indicates the state of charge of flooded cell but not the capacity

Cell open circuit voltage = specific gravity + 0.845 The specific gravity of battery is decided on Battery technology Battery application - operating temperature Battery life. Sp. Gravity varies with temperature

How Specific gravity of Acid Influence on Battery?

Higher gravity
More capacity Shorter life Less space Better cranking

Lower gravity
Less capacity Longer life More space Poor cranking

Typical specific gravities for certain applications are

1.30 1.28 1.26 1.25 1.22 1.20 VRLA (in general) Heavily cycled batteries -traction Automotive (SLI) UPS/Solar photovoltaic (SPV) Train lightings General applications such as power utility

Since 1977

The benefits

No water top up Long life on float service Excellent shelf life No corrosive fumes Ready to use Stackable with horizontal orientation Low weight and volume Safe to use Faster installation
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Since 1977

Performance Characteristics

Ampere hour efficiency Watt hour efficiency Self discharge Oxygen recombination efficiency

: >95 % : >85% : less than 3% per month : >98%

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Effects of Discharge Rate and Temperature on Battery

Less the rate of discharge more the capacity
Battery of 100Ah @ 10Hr rate give around 50Ah @ 1 Hr. rate

Less the operating temperature less the capacity more the life

More the depth of discharge less the life

BATTERY APPLICATIONS Starting, Lighting, and Ignition (SLI) Momentary high rate Partial float Low capacity Pasted plate design. Traction Motive power for electric or hybrid vehicles High capacity to weight and volume ratio Deep cycling Typical applications - Fork lifts, Electric carts Tubular plate design

Stationary Standby battery (UPS and Telecom Equipment) Work Generally in Float Mode Medium to low rate discharge Long backup

Solar Photovoltaic (SPV) Generally stand-alone Re-charged by the solar energy Deep cyclic & PSOC operation

DISCHARGE CHARACTERISTIC CURVES AT 27oC

Since 1977

2.10 2.00

Voltage

1.90 1.80 1.70 1.60

3 CA 2 CA 1 CA 0.7 CA 0.28 CA 0.1 CA

1.50 1 2 4 6 8 10 20 40 60 2 4 6 8 10

Discharge Time
C IS THE RATED CAPACITY OF THE BATTERY. THE AVAILABLE CAPACITY DEPENDS ON STATE OF CHARGE AND ON TEMPERATURE
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Since 1977

Capacity Variation with Temperature

Capacity Variation with Temperature

120 110 100 90 80

Rated Capacity in %

70 60 50 40 30 20 10 0 -30

-25

-20

-15

-10

-5

10

15

20

25

30

35

40

45

50

55

60

Temperature in C

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Battery charging Methods

A. Constant Voltage Charging
Charging the battery at Constant Voltage Current will come down as the Battery gets Charged No chance of High Current charging Dual Mode with FC-BC facility B. Constant Current Charging Charging battery at same current Better charging fast charging High gassing more water loss Appropriate for cyclic operation Not suitable for VRLA (in general)

Split-rate charger more safe as it pumps high initial current to the cell and then switches to a low rate based on time of charge, voltage or both.

c. Boost charging
Fast charging at higher voltage when battery discharges to higher depth Generally Float cum Boost chargers are used in VRLA battery charging in site

D. Trickle Charging
Continuous constant-current charge at off line

E. Equalizing Charge
Equalize the cell voltage in Battery bank to avoid over/under charge of cells