VRLA cell

Instead of simple vent caps on the cells to let gas escape, VRLA have pressure valves that open only under extreme conditions.

VRLA cell
Valve-regulated batteries also need an electrolyte design that reduces gassing by impeding the release to the atmosphere of the oxygen and hydrogen generated by the galvanic action of the battery during charging. This usually involves a catalyst that causes the hydrogen and oxygen to recombine into water and is called a recombinant system. Because spillage of the acid electrolyte is eliminated the batteries are also safer.

VRLA advantages
No water top-up required throughout its life Maintenance-free No special battery rooms, as no corrosive fumes Better foot print due to stack able design Safe to use - leak and explosion proof Ease of installation and ready to use-supplied in factory charged condition Eco-friendly, cadmium-free alloy for ease in recycling Simple cell replacement capability

BATTERY CHARGING
It is an electro chemical process of passing an direct current (D.C) through the battery in a direction opposite that of discharge, the lead sulphate is decomposed and gradually restoring to its original state and ready to deliver electricity again METHODS OF CHARGING Constant current method Constant potential method

Constant current charging system

The rate of current is maintained constant till the end of charge irrespective of the rise of voltage. This method is employed for initial charging of lead acid cells. A higher charging rate is permissible in the initial stages till the potential rises to 2.3 volts, after which it should be reduced to avoid loss of electrolyte due to excessive gassing and undue rise in temperature of the plates

Constant potential charging

A fixed rate at 2.4 volts per cell is maintained without any ballast resistance in circuit. The initial charging current is very high especially if the battery is completely discharged. Hence, it is used only for batteries which are not normally discharged to a very low value.

Charging Systems
Constant current method Initial Charging Boost Charging Constant potential method Trickle Charging Float Charging Equalizing Charging Normal Charging Freshening Charging

Initial Charging
it is always preferable to follow the instructions of manufacturer in reference to specific gravity of electrolyte, charging current, discharging current, total time the cell should be kept on charge etc this first charge is not to be terminated till the specified ampere hour capacity is put into the battery, notwithstanding constant or higher values of Sp. Gr. and voltages being obtained earlier.

Initial Charging
The initial charging shall be carried out in the following steps
1. 2. 3. 4. 5. Preparation of Electrolyte Testing of battery/cell (Physical condition) Filling of electrolyte in battery/cell Supply of electrical energy/Charging and Drawing back the Electrical Energy/Discharging

Initial Charging
Voltage supplied should be at the rate of 2.7V per cell Current should be maintained constant throughout the initial charge (AH capacity/15)

Readings of Sp.Gr. And voltage of each cell may be taken at intervals of 8 hours, after 50 hours of charge, take hourly readings. The voltage will reach a final value of 2.50 to 2.55 V per cell, and the specific gravity to 1.210

Initial Charging
Discharge it at a current which is less than AH capacity /10 till any one of the cell voltage reaches 1.75V or total battery voltage equals to 1.85 X no of cells

Charge again at AH/10 rate till free gassing appears

This charge and discharge cycles to be continued for 2 to 3 times to get maximum capacity

Trickle Charge Working

A system in which battery comes into operation only during emergencies. At other times the battery is idle and maintained in charged condition by trickle charging at 2.25 to 2.30 volts per cell. The trickle charge current will be approximately 1 mA per AH at the rated 10 Hour capacity of the battery

Float Charge Working

system in which the battery is connected in parallel to the charger or DC source and load. The correct float charger current is automatically controlled by maintaining the correct float voltage across battery terminals. The voltage of the source is slightly greater than the open circuit voltage of the battery (2.15V to 2.20 volts per cell)

Equalizing Charge
A periodical charge given to the battery to correct any inequalities of Sp.Gr. among cells developed during service. An equalising charge is given at a rate of 10Hr Cap/50. the frequency of the refreshing charge is once in six months only

Boost Charge
Given to a battery when it is neither possible nor practicable to give it a regular charge. This is usually a charge of higher rate and shorter duration in order to prevent overdischarging of the battery. It is given at rate 2.4V Cell.

The chief troubles to which the battery is subjected to are

Sulphation Buckling Internal short circuit Internal discharge Loss of capacity Low density of electrolyte High density of electrolyte Reverse Voltage Shedding Sludge Open Circuit Temperature Troubles

Sulphation
Indication Cause white patches are observed on terminals indication is loss of capacity due to excessive discharge discharged condition for a long period impurities in the water or acid Low level of electrolyte

Treatment

charge at 1/3rd of the normal rate, till the cell deliver gas freely. Discharge at the same rate. Repeat the cycle till the voltage of the cell reaches 2.35 on charge and specific gravity is as per manufacturer's rating

Buckling
Indication The plates become saucer shape or cup like with twisted or bulged ends tending to touch or touching the sides of the container or adjacent plates Excessive discharge or charge, bad sulphation If not very badly bent, the plates can be removed, straightened in a vice or press. If very badly bent, they should be replaced

Cause Treatment

Internal short circuit

Indication

The cell will be warm even when idle, specific gravity and voltage will be low immediately after charge. There will be no gassing
Due to fallen pieces of hard sulphate, bending or treeing, high degree of sulphation If not very badly bent, the plates can be removed, straightened in a vice or press. If very badly bent, they should be replaced Fallen pieces should be removed. Excess sulphation or sludge, treatment as in sludge.

Cause

Treatment

Internal Discharge Indication Cause Treatment The cell discharges faster, warm even in idle condition, less capacity Impurities inside the cell Electrolyte replaced

Loss of Capacity Indication Cause Treatment The cell discharges faster, it may not be warm when idle. slight sulphation or slight buckling or aging or impurities Attend as in case of sulphation and buckling and internal discharge

Reverse voltage of cells

Indication Cause The positive and negative terminals will show opposite polarity. Cell which got discharged already when the others are being discharged, gets charged in the wrong direction by the main discharge current passing through it. This results in the positive plate being partially converted into spongy lead and the negative plate into lead peroxide. This causes a reverse voltage and acts in the opposite direction to the main battery emf.

Treatment

Remove the discharged cell Remove the cause of defect and give slight charge

Shedding
Indication Cause Treatment Slight loss in capacity or short circuit in the case of very severe shedding. Due to excessive gassing, thereby dislodging peroxide paste from the grids or due to sulphation. Replace cell if severe, otherwise give slight charge at low rate.

Sludge
Indication This is the name given to the peroxide or sulphate sediments collected at the bottom of the jar Loss of capacity or short circuit, visible in the case of transparent container.
Bad maintenance, excessive gassing, shock and vibration, excessive sulphation Wash the plates and re-charge at low rate with fresh electrolyte in the case of slight formation. In the case of severe formation replace the cell.

Cause Treatment

 Each cell shall be tested individually with a load of 10 ohm resistance and if the voltage of cell falls below 0.85V, then the cell shall be discarded. The voltmeter used for this purpose shall have the sensitivity of not less than 1000 ohms per volt.

Rating of battery charger

The current rating of battery charger may be derived from the following formula Current rating of charger = Load current + AH capacity of cell