OPERATION AND MAINTENANCE OF

VRLA BATTERIES

INTRODUCTION
Maintenance free, valve-regulated
lead-acid (VRLA) batteries ensure a
reliable, effective and user friendly
source of power. It is spill proof, leak
proof and explosion resistant and
there is no need to add water or to
clean terminals. It has low selfdischarge rate which eliminates the
need for equalizing charges. The
container is made of polypropylene.
Each plate is individually wrapped by

The chemically inert gas ensures life long

service. The absorbed electrolyte ensures
that there is no spillage even in the unlikely
event of puncture of the cell. Gas evolution
under float conditions is negligible. The
water loss throughout life due to gassing is
roughly 0.1% of the total electrolyte
present in the cell. This will in no way affect
performance and also eliminate the need
for specially ventilated battery room and
acid resisting flooring. As the batteries can
be installed in stacks, there will be
considerable space saving also.

VRLA Technology A brief review

1.Reaction at positive plate:
H2 O
= O2 + 2e
2.Reaction at negative plate :
Pb + 1/2O2 = PbO
PbO + H2SO4

(1)

(2)
= PbSO4 + H2O

(3)

To reaction (1)
PbSO4 + 2H+ + 2e = Pb + H2SO4 (4)
To reaction (3)
To reaction (2)
3.The total reaction at negative plate
O2 + 2H+ =

H2 O

1
2
3
4

Technical Specification of 1000 AH

Battery

Capacity of the Battery @10 H r.

rate discharge to 1.75 ECV
Nominal Voltage per cell of fully
charged battery at 27oC
Open Circuit Voltage (OCV) of
fully charged battery at 27oC
Recommended
Float
Voltage
Condition
(i) Terminal Voltage of Charger
(ii) Float charging current at 2.25
V/ cell

1000 A H
2.0 V
2.15 V

2.25 V/ Cell
Maximum current to
be limited to 20% of
the rated A H
Recommended Boost charging 2.30 V/ Cell
condition for quick charging at
27oC
Internal resistance of the cell
0.257 milli ohms

Life Expectancy of 4000 Cycles at 20% Depth of

the Battery
Discharge or 20 years under
Float condition

Containers:
(i) Material

(ii) Thickness of
wall

Polypropylene (Spl. Grade)

2.3 mm (Approx.)

Fig. Power Stack Cell Cut Section

Freshening Charge
Batteries lose some charge during as well as
during the period prior to installation. A battery
should be installed and given a freshening
charge after receipt as soon as possible.

Constant Voltage Method

Constant voltage is the only charging
method recommended. Most modern
chargers are of the constant voltage type.

Determine the maximum voltage that may be

applied to the system equipment. This voltage,
divided by the number of cells connected in
series, will establish the maximum volts per cell
(VPC) that may be used.
Table B lists recommended voltages and charge
times for the freshening charge. Select the
highest voltage the system allows but not
exceeding 2.37 volts per cell to perform the
freshening charge in the shortest time period. The
charging current should be limited to a maximum
of 20% of the rated capacity in Amps.
Table B
Cell Volts
Time
2.25
30 hrs

Note : Time periods listed in Table B are for

temperatures from 15oC to 40oC. For
temperatures below 15oC double the
number of hours.

Operation:
Floating Charge Method
In this type of operation, the battery is
connected in parallel with a constant voltage
charger and the critical load circuits. The
charger should be capable of maintaining the
required constant voltage at battery
terminals and also supply normal connected
load where applicable. This sustains the
battery in a fully charged condition and also
makes it available to resume the emergency
power requirements in the event of an AC
power interruption or charger failure.

Operation:
Float and Boost Voltages
The average Volts per cell (VPC) value of the series string should be
set to the recommended voltage under Float and Boost conditions.
RECOMMENDED FLOAT VOLTAGE 2.25 VPC AT 27oC
RECOMMENDED BOOST VOLTAGE 2.30 VPC AT 27oC
Modern constant voltage output charging equipment is recommended
for the floating charger method of operation of batteries
The charging current for the battery should be limited to 20% of its
nominal AH capacity. After the battery has been given its freshening
charge , the charger should be adjusted to provide the recommended
float voltage at the battery terminals.
Do not use float voltage lower or higher than those recommended.
This will result in reduced capacity and/or reduced battery life. If
normal battery float voltage is above or below the recommended
value adjust charger to provide proper voltage as measured at the
battery terminals.

Voltmeter Calibration
Panel and portable voltmeters used to indicate battery
voltage should be accurate at the operating voltage
value. The same holds true for portable meters used to
read individual cell voltages. These meters should be
checked against a standard every six months and
calibrated when necessary.
Recharge
All batteries should be recharged as soon as possible
following a discharge with constant voltage chargers.
Temperature of the Cell
The temperature of the POWER STACK cells cannot be
measured during operation. However, cell temperatures
are normally within +5oC of the ambient. All
performance characteristics are measured at ambient
temperature and corrected to 27oC.

Determining State-of-Charge
While charging the current shown by the charger
ammeter will start to decrease and will finally
stabilize when the battery becomes fully charged, if
the normal connected load is constant (no
emergency load connected). The state when the
current level remains constant, after it has started
decreasing, for three consecutive hours would
indicate full state of charge condition and the battery
will be ready for normal use.
If the normal connected load is variable (e.g.
Telecom application) the state when the voltage
across the battery terminals is stable for six
consecutive hours would indicate full state of
charge condition and the battery is ready for normal

Equalizing Charge
General
An equalizing charge is a special charge given to
a battery when non-uniformity in voltage has
developed between cells. It is given to restore all
cells to a fully charged condition.
Non-uniformity of cells may result from low float
voltage due to improper adjustment of the
charger or a panel voltmeter, which reads an
incorrect (higher) output voltage. Also, variations
in cell temperatures greater than 3oC in the string
at a given time due to environmental conditions
or module arrangement can cause low cells.

Pilot Cell
A pilot cell is selected in the series
string to reflect the general
condition of all cells in the battery.
The cell selected should be the
lowest cell voltage in the series
string following the initial charge.

Records
A complete recorded history of the battery operation is most
desirable and helpful in obtaining satisfactory performance. Good
records will also show when corrective action may be required to
eliminate possible charging, maintenance or environmental problems.
The following surveillance data must be read and permanently
recorded for review by supervisory personnel so that any necessary
remedial action is taken.
A)Upon completion of the freshening charge and with the battery on
float
charge at the proper voltage for one week, read and record the
following :
1)Individual cell voltage
2)Battery terminal voltage
3)Ambient temperature
B)Every 3 months, a complete set of readings as specified in
paragraph A above
must be recorded.
C)Whenever the battery is given an equalizing charge, an additional
set of
readings should be taken and recorded as specified in paragraph A

Temporary Non-use
As installed battery that is expected to
stand idle for over 6 months should be
treated as follows. Give the battery an
equalizing charge . Following the equalizing
charge, open connections at the battery
terminals to remove charge and load from
the battery.Every six months, temporarily
connect battery to charger and give it an
equalizing charge. To return the battery to
normal service, re-connect the battery to
the charger and load, give an equalizing

Checking Connections
Battery terminals and inter cell connections
should be corrosion free and tight for trouble
free operation. Periodically these connections
should be inspected.
If corrosion is present, disconnect the
connector from the terminal.
Gently clean the affected area using a brush
or scouring pad. Apply a thin coating of
petroleum jelly to the cleaned contact
surfaces, reinstall connectors and re torque
connections.
ALL TERMINALS AND INTERCELL
CONNECTIONS SHOULD BE RETORQUED

Determination of State of Charge of VRLA Batteries

However, in a VRLA battery, it is not possible to measure
the specific gravity of the electrolyte since it is completely
absorbed in the spun glass micro porous separator. The
terminal voltage of the battery is directly related to the
concentration of the electrolyte. Therefore, if one were to
measure the open circuit voltage of the battery, the state
of charge can be determined. The Open Circuit Voltage
(OCV) readings should be taken 24 hrs. after charging is
discontinued. The OCV value is co-related to the state of
charge of VRLA batteries as per the table enclosed.
Sometimes, it may not possible to disconnect the
batteries from service for 24 hrs. And then check the
OCVs. Then the pattern of charging current delivered by a
temperature compensated voltage regulated charger
after a discharge provides the alternate method for
determining the full state of charge. The temperature
o

Under normal conditions the batteries are floated at

around 2.25 volts per cell, i.e. in a DOT system 24 cells
are floated at 53.5 volts. During charging as the cells
approach full charge, the battery voltage rises to
approach the charger output voltage, i.e. 53.5 volts and
the charging current decreases to the float current value
of around 50 mA/100 AH for VRLA batteries. So, when the
charging current has stabilized at the float current for
three consecutive hours or the voltage across the battery
bank terminals is constant for six consecutive hours, then
the battery bank can be considered as having reached full
state of charge.
If the charging voltage has been set at a value higher (but
equal to or less than 2.30 VPC) than normal float voltage
(so as to reduce charging time), it is normal practice to
reduce the charging voltage to the float value of 2.25V
after 12 hrs. Then the float current will soon stabilize and

Table
% State of Charge Open Circuit
Voltage
100 2.15
90 2.13
80 2.11
70 2.09
60 2.07
50 2.05
40 2.03
30 2.01
20 1.97
0
1.95

Thank You