Brief note on VRLA technology

The electrode reactions in all lead acid batteries including VRLA batteries are basically
identical. As the battery is discharged the lead dioxide positive active material and the spongy
lead negative active material both reacts with the sulphuric acid electrolyte to form lead
sulphate and water. During charge, this process is reversed. The coulomb efficiency of the
charging process is less than !!" on reaching final stage of charging or under over charge
conditions, the charging energy is consumed for electrolytic decomposition of water and the
positive plates generate oxygen gas and the negative plates generate hydrogen gas.
#nder typical charging conditions, oxygen at the positive plate occurs before hydrogen
evolution at the negative. This feature is utili$ed in the design of VRLA %atteries. &n flooded
cells, the oxygen gas evolved at the positive plate bubbles upwards through the electrolyte
and is released through the vents. &n VRLA batteries the oxygen gas evolved at the positive
instead of bubbling upwards is transported in the gas phase through the separator medium to
the negative plate. The separator is a highly absorbent glass mat type with very high porosity
designed to have pore volume in excess of the electrolyte volume 'starved electrolyte design(,
due to which the oxygen gas finds an unimpeded path to the negative plate. Reaction with the
spongy reduces the oxygen gas Lead at the negative plate turning a part of it into a partially
discharged condition, there by effectively suppressing the hydrogen gas evolution at the
negative plate. This is what is )nown as the oxygen recombination principle.
The part of negative plate that was partially discharged is then reverted to original spongy
lead by subse*uent charging. Thus a negative plate )eeps e*uilibrium between the amount
which turns into spongy lead by charging and the amount of spongy lead which turns into lead
sulphate by absorbing the oxygen gas generated at the positive plate. The oxygen
recombination principle can be shown by the following reaction mechanism.
from the above e*uation it can be seen that the reaction is reversible and based on which the
lead acid battery is classified as secondary battery which can give no. of discharge and charge
cycle. During discharge the lead dioxide in positive plate and spongy lead in negative plate
react with sulphuric acid in the electrolyte to from lead sulphate both in positive and negative
plates and water in the electrolyte. The chemical reactions for the same are shown below.
What is Shelf life of VRLA battery Consequences of prolonged storage of
battery with out freshening charge. Why freshening charge is required for
VRLA battery?
A VRLA battery comes in fully charged condition. +or any battery ,helf discharge is common
observed phenomenon. During self-discharge the active material on the plates gets a
converted into sulphate that is discharge compound. This is called .sulphation/ which means
the formation of lead sulphate on the surface and in the pores of the active material of the
plates. The reason for this is as follows.
Lead sulphation is formed as a result of local action or self-discharge of the plates. This
happens by the action of the acid solution on the active material of the plates. ,ulphation is a
necessary part of the operation of battery and is not a source of trouble. The rate of
sulphation depends on the concentration of the electrolyte and the ambient temperature.
This sulphation of plates will reduce performance of the battery drastically during service if it
is not treated properly. This can easily be reduced0removed by charging the batteries at a low
rate of current 'say 1" of Ah capacity( for a prolonged duration of 2! hrs. &f the batteries are
stored for more than the specified period, it is strongly recommended that they should be
charged as per the above before putting in to service.
3enceforth it is recommended that once in six months the battery shall be given freshening
charge if they are connected to Load.
+or freshening charge details pls. Refer 4 5 & manual.
!ternal factors effect on Life of V R L A battery
The life of the VRLA batteries li)e any other battery depends on various parameters li)e depth
of discharge, charging voltage, ripple content, voltage regulation, operating temperature,
nature of application, monitoring procedure followed etc., The effect of each of the above
parameters have been briefly described below.







6onitoring7 VRLA batteries are no doubt 6aintenance +ree types. 3owever they do re*uire
certain monitoring to be carried out on the battery set as well as charging e*uipment apart
from periodical boost charging at an interval of once in six months 'once in 8 months is
preferred( to derive optimum performance0life. The international standards &999 ::7;;2
'&999 recommended practice of maintenance, testing and replacement of VRLA batteries for
stationary applications( also recommend certain maintenance0monitoring procedures to
optimi$e the life and performance of VRLA batteries. +or further details pls. Refer 4 5 &
manual.
Con"entional
Batteries Vs
VRLA batteries
<onventional %atteries
VRLA BA##R$
Regular maintenance re*uired
involving topping up with distilled
water.
=o periodic topping since this
battery wor)s on the oxygen
recombination reaction resulting in
no water loss. 3ence no
maintenance problems such as
brea)age or >amming up of floats.
A lot of excess free acid is available
leading to acid stratification. This is
more pronounced in larger cells.
=o stratification of the electrolyte
because of the ?ic)ing action of the
absorbent separators. The cells are
mounted hori$ontally, reducing the
height of cell, 3ence ,tratification is
therefore eliminated.
There is a possibility of ground
currents due to electrolyte spillage.
This can result in high rates of self-
discharge.
There is no possibility of electrolyte
spillage due to the spill proof and
lea) proof construction. 3ence
ground currents are eliminated.
=ormal vent plugs. %atteries are fitted with explosion
proof safety valves, which can@t be
opened without a special tool.
Aost corrosion is usually observed
due to the acid spillage0mist etc.
=o post corrosion, since there is no
acid spillage0mist.
<over sealed to hard rubber
container with bitumen compound.
<rac)ing and de-bonding of this
bitumen compound is a very
common problem.
<ell covers and >ars are hermetically
heat-sealed. ,ince no third element
is used for sealing operational
problems are not envisaged.
%ulging of hard rubber container
due to hydrostatic thrust is normal.
&ndividual plastic cells are housed in
6, trays. 3ence no dimensional
change is observed in service.
The average discharge voltage is
.;8VA<.
VRLA batteries have very good
discharge regulation. The average
discharge voltage at <! rate is
.;B VA<. 3ence greater power is
available from these batteries.
,eparate battery room with acid
resistant flooring and proper
exhausts for ventilation is a must.
VRLA batteries can be located next
to the charger or next to the
controls. =o separate battery room
is re*uired. 3ence reduction in
copper bus0cables from charger to
battery and battery to system.
,elf discharge rates of up to C" of
capacity per wee).
Very low self-discharge of around
.!" of capacity per wee).
Re*uires good ventilation with
exhaust +ans
=ormal ventilation is sufficient as
per uniform building code.
9*uali$ing charge is re*uired. =o e*uali$ing charge is re*uired.
Transit damages are high because
of brittle rubber containers.
,ince VRLA batteries are housed in
steel trays the transit damages are
minimal.
&nitial charging is done at site. This
increases the time and space
re*uirements.
These batteries are factory charged.
3ence <ommissioning is immediate
and no initial charging at site is
re*uired. An :!" saving in
installation time is *uite common.
Design life expectancy is ! Dears. Design life expectancy is EB years.
%ther intangible benefits include in VRLA batteries&
<onventional %atteries
VRLA BA##R$
Regular maintenance re*uired
involving topping up with distilled
water.
=o periodic topping since this
battery wor)s on the oxygen
recombination reaction resulting in
no water loss. 3ence no
maintenance problems such as
brea)age or >amming up of floats.
A lot of excess free acid is available
leading to acid stratification. This is
more pronounced in larger cells.
=o stratification of the electrolyte
because of the ?ic)ing action of the
absorbent separators. The cells are
mounted hori$ontally, reducing the
height of cell, 3ence ,tratification is
therefore eliminated.
There is a possibility of ground
currents due to electrolyte spillage.
This can result in high rates of self-
discharge.
There is no possibility of electrolyte
spillage due to the spill proof and
lea) proof construction. 3ence
ground currents are eliminated.
=ormal vent plugs. %atteries are fitted with explosion
proof safety valves, which can@t be
opened without a special tool.
Aost corrosion is usually observed
due to the acid spillage0mist etc.
=o post corrosion, since there is no
acid spillage0mist.
<over sealed to hard rubber
container with bitumen compound.
<rac)ing and de-bonding of this
bitumen compound is a very
common problem.
<ell covers and >ars are hermetically
heat-sealed. ,ince no third element
is used for sealing operational
problems are not envisaged.
%ulging of hard rubber container
due to hydrostatic thrust is normal.
&ndividual plastic cells are housed in
6, trays. 3ence no dimensional
change is observed in service.
The average discharge voltage is
.;8VA<.
VRLA batteries have very good
discharge regulation. The average
discharge voltage at <! rate is
.;B VA<. 3ence greater power is
available from these batteries.
,eparate battery room with acid
resistant flooring and proper
exhausts for ventilation is a must.
VRLA batteries can be located next
to the charger or next to the
controls. =o separate battery room
is re*uired. 3ence reduction in
copper bus0cables from charger to
battery and battery to system.
,elf discharge rates of up to C" of
capacity per wee).
Very low self-discharge of around
.!" of capacity per wee).
Re*uires good ventilation with
exhaust +ans
=ormal ventilation is sufficient as
per uniform building code.
9*uali$ing charge is re*uired. =o e*uali$ing charge is re*uired.
Transit damages are high because
of brittle rubber containers.
,ince VRLA batteries are housed in
steel trays the transit damages are
minimal.
&nitial charging is done at site. This
increases the time and space
re*uirements.
These batteries are factory charged.
3ence <ommissioning is immediate
and no initial charging at site is
re*uired. An :!" saving in
installation time is *uite common.
Design life expectancy is ! Dears. Design life expectancy is EB years.
Co'parison
between S()*
VRLA and
S()*
Auto'oti"e
Batteries
S()*VRLA batteries S()*Auto'oti"e batteries
?or)s on 4xygen recombination
principleFFF..hence no need for
topping up over the lifetime.
+looded design with low gassing
<haracteristicsFmore electrolyte
reservoir to address the water loss.
=eeds topping once in 2 months or
year. Reducing the water loss rather
than combining oxygen and
hydrogen inside the battery
achieves $ero-maintenance
<haracteristics.
The battery can meet high rate
discharge as well as steady load
long discharge applications.
The battery was designed for
vehicle starting 'cran)ing(
application. =ot superior in terms of
long discharge
applications0re*uirements '01 hr
and above(
Rugged construction allows no
sedimentation of active material
and short-circuiting during transit
and service.
+looded electrolyte design prone to
active material shedding and short
circuits.
Totally ,ealed construction
=ot a totally sealed
batteryF..venting devise will have
access to add water or acid.
9xplosion proof vent plug is
provided and hence safer.
=o explosion proof vent plug is
provided and it is only an anti
splash type. &nstallation in confined
spaces is a safety 3a$ard as the
accumulation of pent up gases will
ignite and explode.
Aerfect spill 5 lea) proof, hence
user friendly and office compatible.
Due to the free electrolyte in the
battery, chances of spillage, Lea)s
5 fumes are possible.
Aatented alloy positive grid imparts
the superior cyclic life and good for
deep cycling applications.
Generally the automotive battery
positive grids made with Lead
calcium based alloys will have poor
cyclic capabilities due to the
passivation of positive plate during
discharge cycle. This will be more
pronounced in Lead <alcium
,ystems. Lead Antimony is not 6+
The float currents will be low 5 &t
will be stable throughout out the life
of the battery.
4ver a period of time the float
current will increase because of grid
corrosion, Alate expansion etc.
,elf discharge is very Low H" ,elf discharge comparatively high.
3as .:-1.B mm approx. Absorptive
Glass 6at AG6 separator which will
prevent short circuit.
The separator is thin usually .! to
.B mm thic) to facilitate low
internal Resistance for high starting
currents. #A, has no similar
application need. The short circuit is
a ma>or failure mode.
Life -9ven in ideal start-light-ignition the primary application ,L& batteries are intended for
life is less than 82 months.
S()*VRLA batteries S()*Auto'oti"e batteries
?or)s on 4xygen recombination
principleFFF..hence no need for
topping up over the lifetime.
+looded design with low gassing
<haracteristicsFmore electrolyte
reservoir to address the water loss.
=eeds topping once in 2 months or
year. Reducing the water loss rather
than combining oxygen and
hydrogen inside the battery
achieves $ero-maintenance
<haracteristics.
The battery can meet high rate
discharge as well as steady load
long discharge applications.
The battery was designed for
vehicle starting 'cran)ing(
application. =ot superior in terms of
long discharge
applications0re*uirements '01 hr
and above(
Rugged construction allows no
sedimentation of active material
and short-circuiting during transit
and service.
+looded electrolyte design prone to
active material shedding and short
circuits.
Totally ,ealed construction
=ot a totally sealed
batteryF..venting devise will have
access to add water or acid.
9xplosion proof vent plug is
provided and hence safer.
=o explosion proof vent plug is
provided and it is only an anti
splash type. &nstallation in confined
spaces is a safety 3a$ard as the
accumulation of pent up gases will
ignite and explode.
Aerfect spill 5 lea) proof, hence
user friendly and office compatible.
Due to the free electrolyte in the
battery, chances of spillage, Lea)s
5 fumes are possible.
Aatented alloy positive grid imparts
the superior cyclic life and good for
deep cycling applications.
Generally the automotive battery
positive grids made with Lead
calcium based alloys will have poor
cyclic capabilities due to the
passivation of positive plate during
discharge cycle. This will be more
pronounced in Lead <alcium
,ystems. Lead Antimony is not 6+
The float currents will be low 5 &t
will be stable throughout out the life
of the battery.
4ver a period of time the float
current will increase because of grid
corrosion, Alate expansion etc.
,elf discharge is very Low H" ,elf discharge comparatively high.
3as .:-1.B mm approx. Absorptive
Glass 6at AG6 separator which will
prevent short circuit.
The separator is thin usually .! to
.B mm thic) to facilitate low
internal Resistance for high starting
currents. #A, has no similar
application need. The short circuit is
a ma>or failure mode.
Co'parison of +i*Cd Batteries Vs VRLA Batteries
=i-<d %atteries VRLA BA##R$
.1 volt 0 cell system i.e more cells
per a given ban) voltage
1.!volt0cell system i.e. less cells per
a given ban) voltage.
Very 9xpensive '8 to C times(. Very cost effective.
Vent pulgs are of conventional float
type.
Vent plugs are of explosion proof
safety valve type.
=ormal vent plugs. %atteries are fitted with explosion
proof safety values, which can@t be
opened without a special tool.
Very bul)y in weight. ?eight 8!" less
4ccupies more space. 4ccupies C!" less space.
Re*uires separate battery room.
Doesn@t re*uire any separate battery
room.
Re*uires good ventilation with
9xhaust fans.
=ormal ventilation is sufficient.
,pillage 5 Lea)s are possible. ,pill 5 Lea) Aroof.
Re*uires very long &nitial charging
process at the customer@s sites.
=o initial charging re*uired.
=eeds an additional wooden rac) for
installation.
<omes in self stac)able steel trays.
<an@t be transported in charges
condition.
<an be transported in charged
condition.
They need to be stac)ed vertically
only.
<an be stac)ed in any direction.
Regular 6aintenance is re*uired. =o regular maintenance.
6onitoring of the system and
charger is re*uired.
6onitoring of the system and charger
is re*uired.
,eat generation fro' battery ban- during )loat . Boost 'ode *calculation
Generally heat will generate from battery during +loat 5 boost charging mode. The heat
calculations during these modes of charging are as follows. +loat mode the heat generation in
?att-3rs for 1V <ell.
%oost mode the heat generation in ?att-3rs for 1V cell.
I !.1 x 1.8 x Ah J<! x =o. of cells in the battery ban)
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!!
/#
op
A'ount of ,ydrogen gas that will e"ol"e fro' the battery during tric-le
'ode.
The 31 gas evolved form a battery ban) I
I !. x Ah capacity J <! x ;.!B2 x =o. of cells in the battery ban). <<03r
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!
Battery C$CL Life Vs L0)
A battery LcycleL is one complete discharge and recharge cycle. &t is usually considered to be
discharging from !!" to 1!", and then bac) to !!". 3owever, there are often ratings for
other depth of discharge cycles, the most common ones are !", 1!", and B!".
%attery life is directly related to how deep the battery is cycled each time. &f a battery is
discharged to B!" every day, it will last about .B times as long as if it is cycled to :!" D4D.
&f cycled only 1!" D4D, it will last about 1 times as long as one cycled to B!". 4bviously,
there are some practical limitations on this - you don@t usually want to have a B ton pile of
batteries sitting there >ust to reduce the D4D. The most practical number to use is B!" D4D
on a regular basis. This does =4T mean you cannot go to :!" once in a while. &t@s >ust that
when designing a system when you have some idea of the loads, you should figure on an
average D4D of around B!" for the best storage vs cost factor. Also, there is an upper limit -
a battery that is continually cycled B" or less will usually not last as long as one cycled down
!". This happens because at very shallow cycles, the Lead Dioxide tends to build up in
clumps on the positive plates rather in an even film.
A1( batteries ha"e se"eral ad"antages o"er both 1elled and )looded2 at
about the sa'e cost as 1elled
,ince all the electrolyte 'acid( is contained in the glass mats, they cannot spill, even if bro)en.
This also means that since they are non-ha$ardous, the shipping costs are lower. &n addition,
since there is no li*uid to free$e and expand, they are practically immune from free$ing
damage.
=early all AG6 batteries are LrecombinantL - what that means is that the 4xygen and
3ydrogen recombine &=,&D9 the battery. These use gas phase transfer of oxygen to the
negative plates to recombine them bac) into water while charging and prevent the loss of
water through electrolysis. The recombining is typically ;;M" efficient, so almost no water is
lost.
The charging voltages are the same as for any standard battery - no need for any special
ad>ustments or problems with incompatible chargers or charge controls. And, since the
internal resistance is extremely low, there is almost no heating of the battery even under
heavy charge and discharge currents.
AG6@s have a very low self-discharge - from " to 8" per month is usual. This means that
they can sit in storage for much longer periods without charging than standard batteries. The
Aower stac) batteries can be almost fully recharged ';B" or better( even after 8 days of
being totally discharged.
AG6@s do not have any li*uid to spill, and even under severe overcharge conditions hydrogen
emission is far below the C" max specified for aircraft and enclosed spaces. The plates in
AG6@s are tightly pac)ed and rigidly mounted, and will withstand shoc) and vibration better
than any standard battery.
9ven with all the advantages listed above, there is still a place for the standard flooded deep
cycle battery. &n many installations, where the batteries are set in an area where you don@t
have to worry about fumes or lea)age, a standard or industrial deep cycle is a better
economic choice. AG6 batteries main advantages are no maintenance, completely sealed
against fumes, 3ydrogen, or lea)age, non-spilling even if they are bro)en, and can survive
most free$es. =ot everyone needs these features.
Why Aging factor for Battery si3ing calculation
The performance of any lead acid battery is relatively stable throughout most of its life, but
begins to decline with increasing rapidity in its latter stages. The decline will be very drastic
once the capacity drops to :!" of its rated capacity and there will be little life to be gained by
allowing operation beyond this point.
&n order to ensure that the battery meets the given duty cycle even at the end of its life 'i.e.
at :!" performance level( it is a prudent practice to consider a factor of .1B, which is
normally referred to as NAging +actorO or NLife +actorO . %ut it is not necessary that the battery
be replaced only when its capacity reaches :!", and it can be done even at higher values of,
say :B" or ;!". &n such cases the aging factors to be considered will be .P or .! etc.
respectively.
The &nternational standard &999 Ltd., CB!-;;B states that, .The recommended practice is to
replace the battery if its capacity as determined in 2.B is below :!" of the manufacturerOs
rating if the battery was si$ed using a .1B aging factor. &f a lesser aging factor was used,
battery replacement will be re*uired before :!" capacity is reached to ensure that the load
can be served 'consult the battery manufacturer(./
The timing of the replacement is a function of the design0si$ing <riteria utilised and the
capacity margin available, as compared to the load re*uirements. A capacity of :! " shows
that the battery rate of deterioration is increasing even if this is ample capacity to meet the
load re*uirements of the D< system.
Ageing factor one should consider while si$ing the battery Ah capacity depending upon the
end of life capacity specified by the end user.
(onitoring chart for VRLA batteries (aintenance reco''endations for
VRLA battery.
,ow do 0 get opti'u' life of VRLA battery?
What is the 'aintenance that has to carry on VRLA batteries.
Sl.
No
4escription (onthly 5tly ,ly $early
.
<hec) the float charging voltage and current. As
per the 456 6anual

1.
=ote down the average ambient %attery room
temperature. '%attery will give optimum
performance when operated J 1P!<.(

8.
<hec) the charger ripple and the regulation.
'Ripple7 H1" rms. Value, Regulation7 K ".(

C.
<hec) the over voltage cut off and under
voltage trip. Al refer the 456 6anual

B.
%oost charge the batteries for 1C 3rs. Al refer
the 456 6anual

2.
=ote down individual cell 0 6odule voltage
readings after discharging the battery ban) for
B min with the available load <urrent of !"
to 1!" of the rated capacity to identify wea)
cells if any.

P. &nspect for any Ahysical damages, <rac)s on
cover 5 container.'st time before installation
5*uarterly afterwards(

:. <hec)ing the terminal %olts tightness

AC ripple "oltage and current effects on battery perfor'ance.
The achievement of optimum life form a VRLA battery system can also be related to the
*uality of the D< output voltage of the charger. The output should be as pure D< as is
practical for the D< output voltage of the charger. &f the output contains a significant A<
component can cause additional heating of the battery. &f the A< component is sufficiently
large, during a portion of the waveform the charging voltage could actually dip below the
battery 4<V and slightly discharge the battery thus affecting the battery active materials. An
excessive A< ripple effect would be, while the D< helps the battery plates for conversion of
the active materials through the main reaction, the A< component 'i.e. the ripple content(
leads to side reactions. 4ne of the ma>or side reaction is hydrolysis of water thereby liberating
hydrogen and oxygen gases in addition to the hydrogen and oxygen gases liberated from the
main reaction. The gases thus liberated from the main reaction recombine to form bac) as
water in a VRLA battery due to the oxygen recombination principle. The gases liberated from
the side reactions increase the cell internal pressure increases beyond allowable pressure
value the Qsafety valveQ opens and releases these excess gases into the atmosphere. Thus
the batteries are sub>ected to loss of water, eventually results in premature capacity loss.
+urther, due to the availability of abundant *uantities of nascent oxygen gas near the grid
structure, the rate of corrosion of the grid increases drastically, thereby resulting in reduction
of the service life of the batteries.
+or best results, the A< ripple voltage on the charger output should be less than 1" p-p
'pea) to pea)( of the battery D< charging voltage to ensure that the battery will not be
.cycled/.
The A< ripple voltage will induce an A< ripple current and the value of this current will be
related to the value of the voltage and the relatively low impedance of the battery '&I90R(.
This A< ripple current will cause additional heating of the battery, which could affect the
battery life, if significant. The A< ripple current should be limited to !.!B< for best results. +or
example, a !! ampere-hour capacity R battery should experience less than B A< amperes
ripple current for best results.
C67 Capacity #est 8rocedure
10 hr capacity discharge testing method:
The procedure has been prepared by considering with power stac) modules, the same can be
used for Amaron Suanta
T6
batteries.
The following tools are re*uired to test the batteries.
Digital voltmeter '8T digit( - <alibrated.
D< <lamp meter - <alibrated.
,panners set with insulated.
Rubber gloves.
Load ban).
,afety goggles.
Testing procedure:
9nsure that all 6odules terminals tightness with tor*ue =mOs.
9nsure that no damage battery modules in the string and all terminals cleanliness.
9nsure that the battery is in fully charge condition 'i.e. the battery charging current droops
and stabili$es at tric)le value(.
6easure 5 Record the on charge voltages of all the modules in the circuit.
&solate the battery ban) from system. <are should be ta)en to avoid short circuits.
=ecessary arrangements to be ta)en to avoid system interruption during the absence of
battery ban) while testing.
<onnect the external load to battery thru isolation switch. ,witch current capacity should be
two times more than the battery !hr-discharge currents.
,et !hr currents '<! currents I Ah capacity of battery0!(
9x.7 +or !! Ah battery the!hr currents I !!0! I !A D<.
6easure and record the individual module voltage readings as per Annexure U sheet.
%ypass the battery when it reaches to its end cell voltage i.e !.B Volts0battery and
continue the discharge for other batteries.
Bypassing procedure:
Disconnect the load.
Remove the failed module interconnections.
%y-pass the battery from the circuit.
Tighten the terminal bolts to either side of the module.
<ontinue the discharge.
Record the down time 5 extend the discharge test of down time.
After completion of test, connect bac) the battery set as usual to the charging system.
Results interpretation
%attery to be replaced when ever it fails to deliver less than :!" of the rated capacity.
Anne!ure
End user
Location
,ystem
,l. =o.
6fg. Dt. &nst. Dt.
,ystem
rating
Room temperature
Load
current
Duration