10/13/2015

BATTERY TECHNOLOGY FOR DATA CENTERS AND NETWORK

ROOMS
Introduction
VRLA types
VRLA theory of operations
VRLA life expectancy
Failure modes
Battery Settings

BATTERY TYPES(WET CELL)

Absolyte Batteries
Description: Large, lead acid & cadmium, vented (VRLA), rechargeable
Formats: Rectangular in steel racks
Common Uses: Telecommunications systems, railroad switchgear and signals, solar
arrays, Un-interruptible Power Systems (see UPS section)
Safety: Non-spillable, lead is a toxic heavy metal, contains acid electrolyte that is
corrosive if spilled

10/13/2015

BATTERY TYPES(WET CELL)

Large Flooded Cell Batteries
Description: Large, flooded cell batteries, typically lead acid, vented, rechargeable
Formats: Hard case, rectangular
Common Uses: Stationary Power, telecommunications systems, utility systems, Uninterruptible Power Systems (see UPS section)
Safety: Spillable, lead is a toxic heavy metal, contains large quantity of acid electrolyte,
electrolyte corrosive if spilled, extremely heavy

BATTERY TYPES(WET CELL)

Lead Acid Batteries
Description: Medium to large, flooded cell batteries, vented, rechargeable
Formats: Hard case, rectangular, multi-cell
Common Uses: Automobiles, motorcycles, boats, outdoor power equipment
Safety: Spillable, lead is a toxic heavy metal, contains acid electrolyte that is corrosive
if spilled

10/13/2015

BATTERY TYPES(WET CELL)

Nickel Iron Batteries
Description: Medium to large, flooded cell batteries, vented, rechargeable, very long
lasting
Formats: Metal case, rectangular
Common Uses: Railroad signals, mining operations, declining in use to lead acid
batteries
Safety: Spillable, non-toxic

BATTERY TYPES(WET CELL)

Steel Case Batteries
Description: Large, flooded cell batteries, lead acid, vented, rechargeable
Formats: Individual cells within a steel casing
Common Uses: Forklifts, industrial machinery, motive power
Safety: Spillable, lead is a toxic heavy metal, contains acid electrolyte that is corrosive
if spilled

10/13/2015

BATTERY TYPES(WET CELL)

Un-interruptible Power Supply (UPS) Batteries
Description: Medium to large, flooded cell batteries, typically lead acid, vented
(VRLA), rechargeable
Formats: Hard case, rectangular, multi-cell in steel racks
Common Uses: Un-interruptible Power Systems, stationary power
Safety: Non-spillable, contains some acid electrolyte

BATTERY TYPES(WET CELL)

VRLA (Valve Regulated Lead Acid) Batteries
Description: Medium to large, maintenance-free, vented (VRLA), rechargeable
Formats: Hard case, rectangular, multi-cell
Common Uses: Automobiles, motorcycles, boats, wheelchairs, emergency lighting,
Un-interruptible Power Systems (see UPS section)
Safety: Non-spillable, lead is a toxic heavy metal, contains some acid electrolyte

10/13/2015

BATTERY TYPES(WET CELL)

Wet Nickel-Cadmium (NiCd) Batteries
Description: Medium to large, flooded cell batteries, vented, rechargeable, pocketplate and sinter-plate types
Formats: Hard case, tall rectangular, multi-cell
Common Uses: emergency power, telephone systems, solar arrays, hybrid
automobiles (see Hybrid Automobile section also), railroad systems, starting aircraft
turbines and for extreme conditions
Safety: Spillable, cadmium is a toxic heavy metal

ELECTROCHEMISTRY
Fully discharge cells

Negative plate reaction:

Pb(s) + HSO 4(aq) PbSO4(s) + H+(aq) + 2e

Positive plate reaction:

PbO2(s) + HSO 4(aq) + 3H+(aq) + 2e PbSO4(s) +2H2O(l)

The total reaction can be written as
Pb(s) + PbO2(s) + 2H2SO4(aq) 2PbSO4(s) + 2H2O(l)

10/13/2015

ELECTROCHEMISTRY
Overcharging:
Overcharging with high charging voltages generates oxygen and hydrogen gas by
electrolysis of water, which is lost to the cell.

Periodic maintenance of lead-acid batteries requires inspection of the electrolyte

level and replacement of any water that has been lost.

Due to the freezing-point depression of the electrolyte, as the battery discharges

and the concentration of sulfuric acid decreases, the electrolyte is more likely to
freeze during winter weather when discharged

VRLA TECHNOLOGY
Features of VRLA(Valve Regulated Lead Acid)
Container is sealed; liquid cannot be added or removed
Contains lead plates in a solution of sulfuric acid diluted in water (electrolyte)
Electrolyte is immobilized (not allowed to flow)
Operates at high currents
Safety vents allow escape of gas only under fault or excess charging conditions
Oxygen & hydrogen are recombined internally to form water
Installed in open frames or large cabinets (or embedded inside small power
systems)

10/13/2015

VRLA TECHNOLOGY
VRLA types:
Classification on technique for immobilizing the electro-lyte:
Gel cell - in this type of battery the electrolyte is distributed around the cell plates and separators and prevented from flowing by
adding a gel-thickening agent. Gel cells are sometimes preferred for applications such as outdoor cabinets and photovoltaic. They
are more widely used in Europe and Asia than in North America.
Absorbed glass mat (AGM) - in this type of battery a highly porous and absorbent glass fiber mat separates the plates and keeps
electrolyte in contact with them in a manner that is sometimes likened to a sponge. AGM is preferred for most controlled
environment applications such as data centers and network rooms.

Classification on plate types:

So-called telecom or long duration VRLA batteries have thick plates designed to allow the battery to reach its end voltage
over a period of several hours. They are fre-quently not discharged below 1.75 volts per cell.
So-called UPS or high rate discharge VRLA batteries have thin plates designed to allow the battery to reach its end voltage
over a period of only a few minutes. They are typically discharged to around 1.67 to 1.70 volts per cell.

VRLA TECHNOLOGY
VRLA types:
Classification on container types:
Monobloc VRLA is usually a 6-Volt (3 x 2-Volt cells) or 12-Volt (6 x 2-Volt cells) con-tainer. Terminals can be either on top or at
one end of the container. This is far and away the most popular battery for small and medium battery back-up systems in data
centers, network rooms and telecommunications environments.

Modular VRLA are almost always single 2-Volt cells, usually installed horizontally to allow all of their connection and service
from the front of a system. The cells are usually packaged into steel modules that can be stacked one on top of another and
connected in series and/or parallel. This version is most common in telecommunication applications for high power, long duration
back-up.

10/13/2015

VRLA TECHNOLOGY
VRLA types:
Classification on container types:
Battery cartridges are actually multiples of VRLA batteries in a string conveniently packaged to allow their quick installation and
removal. Battery cartridges can be plugged into battery cabinets designed with mating receptacles.

VRLA TECHNOLOGY
VRLATheory of Operation
Why does valve regulation?
Special feature, what is recombination?

10/13/2015

VRLA TECHNOLOGY
VRLA life expectancy
Design life is used by manufacturers as a measure of comparison.
Service life - is the more realistic time (in years) from the installation of the battery
until its capacity falls below 80% of its nominal rating.

VRLA TECHNOLOGY
VRLA batteries dont die theyre murdered.
Variables that can affect the life of a VRLA battery include:
1. Design (variations from one manufacturer to another)
2. Quality of materials (impurities / imperfections)
3. Production methods
4. Quality control
5. Cycling profile
6. Environmental operating conditions
7. Charging regimen

10/13/2015

VRLA TECHNOLOGY
Failure modes
1)High ambient temperature :

VRLA TECHNOLOGY
Failure modes
2) Cycle life
a battery that is seldom used will obviously last longer than a battery that is
discharged and recharged every day.
3) Charging regimen
Frequent Equalize Charging is not recommended

The battery must not exceed the battery manufacturers level of float
voltage(Overcharging can cause dry-out)
Effect of Boost Charge
Most data center and network room UPS recharge the battery to 90% of
nominal capacity in ten times the discharge period. (For example, a 7-minute
discharge would be recharged in 10 x 7 = 70 minutes). Faster recharge will
stress the battery and reduce its life.

10

10/13/2015

VRLA TECHNOLOGY
Failure modes
4) Cell reversal
is associated with large series strings of batteries
is primarily restricted to VRLA batteries.
Conditions:
One cell in a series string has a much lower capacity than the other

cells in the string

The lower capacity cell becomes driven into a reverse condition by the
remaining good cells in the string

the risk of cell reversal in a system design can be nearly eliminated by:
Using parallel strings of batteries
Using a reduced UPS DC bus voltage
Monitoring and control of voltages within the battery string

VRLA TECHNOLOGY
Failure modes
5) Internal failures
negative lug corrosion,
negative strap fracture,
excessive plate growth,
negative plate capacity loss,
Positive grid corrosion
Sediment (shedding) build-up
Top lead corrosion
Plate sulphation
Hard shorts (paste lumps)
and contact between positive plate and negative strap

11

10/13/2015

MANUFACTURER RECOMMENDED PARAMETERS SETTINGS/TEST

Trickle Charging
Float Charge Voltage
Boost Charge Settings
Equalize Charge Settings
Current Limiting
Temperature Compensation On Float Voltage
Self Discharge Test
Partial Discharge Test
Full/Deep Discharge Test

MANUFACTURER RECOMMENDED PARAMETERS SETTINGS

Haze

Voltag
e Per
Block Capacity Float Voltage
Float charge voltage at 200C
6V
200Ah
= 2.27V/Cell
Float charge voltage at 200C
12V
100Ah
= 13.62V/Block
2.23 to 2.27/Cell @ 770F
2V
(2.25 Recommended)
AGM 1.3
4, 6 & to
12 Volt 230AH 2.27 - 2.30 VPC @20 C

OPzV
Hoppecke Range

2V

SB
Hoppecke Range
12CP1
Oerlikon 50

12V

150Ah

2.25/Cell 250C

2.35 VPC (12hrs) or 2.3 VPC (24hrs)

.+/- 3 mV per C

0.25C10

1.80 V/Cell

12V

150Ah

2.25/Cell 250C

2.35 VPC (12hrs) or 2.3 VPC (24hrs)

.+/- 3 mV per C

0.25C10

1.80 V/Cell

BB Make
FIAMM
FIAMM
GNB

Model
6SLA20
0
12FIT1
00
Absolu
te

Boost Voltage

Temperature Cpmpensation
Factor (mV/ 0C per cell)

Final
Maximum Charge Discharge
Current
Voltage

2.35-2.4V/Cell

.+/-2.25mV/C per Cell

0.25C10

1.80 V/Cell

14.1-14.4V/Block

.+/-15mV/C per block

0.25C10

1.80 V/Cell

2.35 VPC (12hrs) or 2.3 VPC (24hrs)

.+/-3V/F (5.5C)

0.25C10

1.80 V/Cell

2.41 @20 C Max. 2.7 VPC Max

ripple 3.5%Charge V

.+/- 3 mV per C

0.25C10

1.80 V/Cell

2.25/Cell 250C

2.35 VPC (12hrs) or 2.3 VPC (24hrs)

.+/-5m V/Cell per C.

0.25C10

1.80 V/Cell

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10/13/2015

BATTERY Discharge Test

1. Partial Discharge Test
2. Deep/Full Discharge Test

V-t Characteristics in Discharge

13

10/13/2015

V-t Characteristics in Discharge

BATTERY DISCHARGE TEST REPORT

DATE

SITE NAME / BANK ID

BANK MODEL & CELL TYPE :

29/01/2015

RECTIFIER

Piliyandala

FLOATING VOLTAGE

54.38

NOMINAL LOAD

108

Hoppecke 10 op2v 1000

Lineage 1500ARectifier

TIME OF READING
just start

30 min

1hr

2hr

3hr

4hr

6hr

7hr

8hr

9hr

10hr

2.400

2.200

2.200

2.200

2.200

2.200

2.200

2.200

2.100

2.100

2.100

2.100

2.1

2.400

2.200

2.200

2.200

2.200

2.200

2.200

2.200

2.200

2.100

2.100

2.100

2.1

2.500

2.200

2.200

2.200

2.200

2.200

2.200

2.200

2.100

2.100

2.100

2.100

2.1

2.400

2.200

2.200

2.200

2.200

2.200

2.200

2.200

2.200

2.200

2.100

2.100

2.1

2.400

2.200

2.200

2.200

2.200

2.200

2.200

2.200

2.200

2.100

2.100

2.100

2.1

2.400

2.200

2.200

2.200

2.200

2.200

2.200

2.200

2.100

2.100

2.100

2.100

2.1

2.400

2.200

2.200

2.100

2.200

2.200

2.200

2.200

2.100

2.100

2.100

2.100

2.1

2.500

2.200

2.200

2.200

2.200

2.200

2.200

2.200

2.100

2.200

2.100

2.100

2.1

2.400

2.200

2.200

2.200

2.200

2.200

2.200

2.200

2.200

2.200

2.100

2.000

2.1

10

2.500

2.200

2.200

2.200

2.200

2.200

2.200

2.200

2.100

2.100

2.100

2.000

2.1

11

2.500

2.200

2.200

2.100

2.200

2.200

2.200

2.200

2.200

2.200

2.100

2.100

2.1

12

2.400

2.200

2.200

2.200

2.200

2.200

2.200

2.200

2.200

2.200

2.100

2.000

13

2.400

2.200

2.200

2.200

2.200

2.200

2.200

2.200

2.200

2.100

2.100

2.100

2.1

14

2.400

2.200

2.200

2.200

2.200

2.200

2.200

2.200

2.200

2.200

2.100

2.100

2.1

15

2.400

1.900

2.100

2.200

2.200

2.200

2.200

2.200

2.200

2.100

2.100

1.900

1.8

16

2.400

2.200

2.200

2.200

2.200

2.200

2.200

2.200

2.200

2.100

2.100

2.000

2.1

17

2.400

2.200

2.200

2.200

2.200

2.200

2.200

2.200

2.100

2.100

2.100

2.100

2.1

18

2.500

2.200

2.200

2.200

2.200

2.200

2.200

2.200

2.100

2.100

2.100

2.100

2.1

19

2.400

2.200

2.200

2.200

2.200

2.200

2.200

2.200

2.200

2.200

2.100

2.000

2.1

20

2.400

2.200

2.200

2.200

2.200

2.200

2.200

2.200

2.200

2.100

2.100

2.100

2.1

21

2.400

2.200

2.200

2.200

2.200

2.200

2.200

2.200

2.200

2.100

2.100

2.100

2.1

22

2.400

2.200

2.200

2.200

2.200

2.200

2.200

2.200

2.100

2.100

2.100

2.000

2.1

23

2.500

2.200

2.200

2.200

2.100

2.200

2.200

2.200

2.100

2.100

2.100

2.100

2.1

24

2.400

2.200

2.200

2.200

2.200

2.200

2.200

2.100

2.200

2.200

2.100

2.100

2.1

Total Volt

54.40

49.00

49.30

49.30

49.00

48.70

48.5

48.1

47.8

47.4

47

46.6

46.1

100

100

100

100

100

100

100

100

100

100

100

100

Before dis

CELL no;

5hr

10hr

CELL VOLTAGE (V)

Dis Current

V-t Characteristics in Discharge

total volts

Battery discharge graph

58.00
57.00
56.00
55.00
54.00
53.00
52.00
51.00
50.00
49.00
48.00
47.00
46.00
45.00
44.00
43.00
42.00

time

14

10/13/2015

V-t Characteristics in Discharge

BATTERY DISCHARGE TEST REPORT
DATE

SITE NAME / BANK ID

2/1/2015

RECTIFIER

Piliyandala

BANK MODEL & CELL TYPE :

power Safe 24 ELE 4OPzV 200

Emerson (BZA 108 08 )

FLOATING VOLTAGE

53.09V

NOMINAL LOAD

25.0A

TIME OF READING
just start

30 min

1hr

2hr

3hr

4hr

6hr

7hr

8hr

9hr

10hr

2.230

2.040

2.020

2.040

2.030

2.020

2.000

1.990

1.970

1.920

1.900

1.900

1.880

2.240

2.040

2.020

2.030

2.020

2.010

2.000

1.980

1.970

1.910

1.900

1.890

1.870

2.230

2.040

2.030

2.040

2.030

2.020

2.000

1.990

1.970

1.930

1.910

1.910

2.230

2.030

2.030

2.040

2.030

2.020

2.000

1.980

1.970

1.920

1.910

1.910

1.880

2.240

2.060

2.030

2.030

2.020

2.010

2.000

1.980

1.970

1.910

1.900

1,.89

1.870

2.240

2.050

2.020

2.040

2.030

2.010

2.000

1.980

1.970

1.920

1.900

1.900

1.870

2.240

2.040

2.030

2.030

2.020

2.010

2.000

1.980

1.970

1.910

1.890

1.890

1.870

2.240

2.040

2.030

2.040

2.030

2.010

2.000

1.980

1.970

1.920

1.900

1.900

2.230

2.050

2.020

2.030

2.020

2.010

2.000

1.980

1.970

1.910

1.900

1.900

1.880

10

2.230

2.040

2.030

2.030

2.020

2.010

2.000

1.980

1.960

1.910

1.860

1.890

1.860

11

2.230

2.040

2.020

2.040

2.030

2.010

2.000

1.980

1.970

1.920

1.880

1.910

1.890

Before dis

CELL no;

5hr
CELL VOLTAGE (V)

1.890

1.880

2.400

2.040

2.030

2.030

2.020

2.010

1.990

1.980

1.960

1.900

1.840

1.880

1.850

13

2.250

2.060

2.030

2.040

2.020

2.010

2.000

1.980

1.970

1.910

1.860

1.890

1.870

14

2.230

2.050

2.030

2.040

2.020

2.010

2.000

1.980

1.970

1.910

1.860

1.890

1.870

15

2.240

2.050

2.030

2.040

2.020

2.010

2.000

1.980

1.970

1.920

1.880

1.910

1.890

16

2.250

2.040

2.030

2.040

2.030

2.010

2.000

1.980

1.970

1.950

1.880

1.910

1.890

17

2.230

2.040

2.040

2.030

2.030

2.010

2.000

1.980

1.970

1.940

1.860

1.890

1.870

18

2.250

2.040

2.040

2.040

2.020

2.010

2.000

1.980

1.970

1.940

1.870

1.900

1.870

19

2.230

2.040

2.030

2.030

2.020

2.010

2.000

1.980

1.970

1.950

1.870

1.900

1.870

20

2.230

2.040

2.020

2.030

2.030

2.010

2.000

1.980

1.970

1.950

1.870

1.890

1.880

21

2.250

2.040

2.030

2.040

2.030

2.010

2.000

1.980

1.970

1.920

1.860

1.900

1.870

22

2.250

2.050

2.030

2.040

2.030

2.010

2.000

1.980

1.970

1.920

1.870

1.900

1.880

23

2.230

2.050

2.030

2.040

2.030

2.010

2.000

1.980

1.970

1.910

1.860

1.900

1.870

24

2.230

2.050

2.030

2.040

2.030

2.010

2.000

1.980

1.970

1.910

1.870

1.900

1.880

Total Volt

53.09

49.67

48.79

48.94

48.69

48.42

48.09

47.71

47.31

46.02

44.85

45.62

Dis Current

20

20

20

20

20

20

20

20

20

20

45.06
20

20

V-t Characteristics in Discharge

total volts

Battery discharge graph

58.00
57.00
56.00
55.00
54.00
53.00
52.00
51.00
50.00
49.00
48.00
47.00
46.00
45.00
44.00
43.00
42.00

time

15

10/13/2015

Best Practices With BB Discharge Test

1) Capacity test (discharge test) should be done
At the installation (acceptance test)
Within the first two years of service
Periodically. Intervals should not be greater than 25% of the expected service
life.
Repeat the above within 2 years for warranty purpose.

2) Make capacity test annually when the battery has reached 85% of expected
service life or if the capacity has dropped more than 10% since the previous
test or is below 90% of the manufacturers rating
3) Make a capacity test if the Impedance value has changed significantly.
4) Replace cell if the impedance is more than 50% above baseline. Make a
capacity test if 20-50% of baseline.
5) Replace battery if capacity test shows less than 60% of rated capacity.
6) Verify that the battery has had an equalizing charge if specified by the
manufacturer
7) Check all battery connections and ensure all resistance readings are correct

Thank You!

16