CSB’s VRLA Battery is small and lightweight that gives high performance making it very economical to use. In addition to these advantages, the sealed construction eliminates the necessity to fill the battery with water.
This handbook describes the construction, technical principles, characteristics, and charge method for CSB’s VRLA Battery to ensure appropriate operation
Battery Features:
Maintenance free
Gas, generated from water electrolysis by overcharge, is absorbed and reduced to an electrolyte by the electrode thus making the battery maintenance free.
Can be installed and operated in any position since gas generation is self-contained and there is no electrolyte leakage
There is no liquid electrolyte because the electrolyte is firmly retained by a retainer and electrodes. However, gas generated from overcharge is absorbed by the electrodes and not expelled outside the battery under normal operations. With this feature, the battery can be used in any position for home & office applications.
Safety measures
Excessive overcharge or an incorrect charging method may produce an extremely large volume of gas. CSB’s VRLA Battery is equipped with a safety valve which detects rising internal pressure, and allows gas to be expelled to the outside.
Ready for use when charged even after extended storage
Using a lead calcium alloy grid structure allows the self discharging quantity to be 1/3 to 1/4 less than the conventional lead antimony grid structure battery. This greatly extends the storage period prolonging battery life.
High performance lead-acid battery
With efficient discharge characteristics and little internal resistance, this battery can be applied to many applications. Principal applications include cycle service with repeated charges and discharges, as well as stand-by use in which the battery is normally maintained in a charged state and discharged only as required.
Economy
CSB’s VRLA Batteries can be used for 260 or more cycles at 100% discharge in cycle service and three to five years in stand-by service. The battery is maintenance free and has a low running cost making it very economical. Its compactness, lightweight and high performances contribute to reducing the overall cost of a power supply system as a whole. (Ambient temperature: 25°C (77°F)).
Battery Applications:
Recently, electronic products are showing remarkable developments. Various communications systems (i.e. VAN, LAN and INS) are quickly advancing to connect portable equipment, OA equipment, and FA equipment.
A power generation system with solar cells utilizing solar energy is also being brought into service. CSB’s VRLA Battery is the most suitable lead-acid battery for main and emergency power supply as well as being an energy storage means. Our products are designed for cycle and stand-by applications.
Specific Applications:
1. Cycle Use:
- Portable VTR/TV, tape recorders, radios, and etc.
- Power tools, lawn mowers and vacuum cleaners
- Cameras and photographic equipment
- Portable personal computers, word processors, portable terminals and etc.
- Portable measuring equipment
- Portable telephone sets
- Various power toys and recreational equipment
- Lighting equipment
2. Standby Use:
- Communications and electric equipment
- Emergency lighting equipment
- Fire alarms and security systems
- Various telemeter equipment
- Office computers, processors and other office automation equipment
- Robots, control equipment and other factory automation equipment
- UPS power supplies
- Emergency power supplies in power generation plants and substations
- Telecommunications
3. Solar Cell Power Generation:
- Street lighting
- Water pumping stations
- Portable handheld power supplies
- Small town power systems
Product Applications
Battery Construction:
The construction of a CSB VRLA battery is shown here. The following is a description of the different parts that make up our batteries.
1. Positive and negative plates
Positive and negative plates consist of active mass and a lead-calcium alloy grid structure.
2. Retainer, adjusting plate
Unwoven glass fiber cloth, with a high oxidation and heat resistance, is used to offer superior electrolyte absorption and retaining ability and satisfactory ion conductivity.
3. Safety valve
The safety valve opens when there is an abnormal increase in internal pressure caused by overcharging or misusage. Gas is released from the battery to return the pressure back to normal.
4. Container and covers
Container and covers are made of ABS or PP resin, with superior strength and acid resistance characteristics. The container and covers are sealed to prevent electrolyte and gas leakage.
Sealing Principle:
The charge/discharge reaction of the VRLA battery can be expressed by the following reaction:
Overcharging causes electrolysis of the water content of the electrolyte, which generates O2 gas at the positive plate and H2 gas at the negative plate. These gasses are then discharged to the outside. Since a drop in the electrolyte levels results, adding water is occasionally needed.
The VRLA battery is designed so that the negative plate does not have to be fully charged even when the positive plate is fully charged. Furthermore, no H2 gas is generated from the negative plate although O2 gas is being generated from the overcharged positive plate. O2 generated from the positive plate then reacts with the charged sponge lead (Pb) of the negative plate and turns into lead monoxide (PbO).
The lead monoxide, in turn, reacts with sulfuric acid (H2SO4) in the electrolyte to turn into lead sulfate (PbSO4), allowing the negative plate to discharge. In other words, O2 from the positive plate is absorbed by the negative plate without being expelled to the outside. Since the negative plate develops discharging with the help of O2, there always exists a portion free from discharging. As a result, the negative plate never generates H2. This completely prevents the loss of water.
The sealing principle of a VRLA battery may be expressed by the following equation:
Charging
The constant voltage charge method is recommended to charge our battery. When charging, the lead sulfate of the positive plate becomes lead dioxide. As charging continues, the positive plate begins to generate O2 causing a sudden rise in battery voltage. A constant voltage charge, therefore, gives rise to detection of this voltage increase and control of the charge amount. This type of charging generally employs a constant-voltage constant-current method with current limitation to prevent the initial current (at low battery voltage) from increasing.
Table 1 shows the charge voltage and maximum charge current. Figures 3 and 4 shows the constant-voltage charging characteristics of the GP1272. Figures 3 and 4 show a constant-voltage charge initially made with a current limited to 0.1CA, with the constant-voltage charge following after the battery voltage reaches a certain level. The battery was charged at the 100% discharge state and the 50% discharged state. A charge quantity of 110-120% of the discharge quantity is needed to fully charge the battery.
The charge voltage of the battery decreases with increasing temperature and vice versa. Accordingly, charging with a given voltage requires an increased charge current when the temperature is high and decreased charge current at a lower temperature. Temperature compensation is not necessary when the battery is charged at an ambient temperature between 5°C (41°F) to 35°C (95°F). At temperatures below 5°C (41°F) or above 35°C (95°F), temperature compensation for charging voltage is necessary.
The temperature coefficient is:
Refer to Figure 5 in order to prevent a poor charge under low temperatures and overcharge under high temperatures, the charging voltage must be set at the appropriate value according to the battery temperature. For the charging voltage of each VRLA battery, refer to Table 1.
Table 1 – Charging voltage and maximum charging current
Figure 3 – GP1272 charging characteristic for constant voltage 14.7V (2.45 V/cell)
(Example of the charging characteristics for the cycle use of CSB VRLA GP series battery.)
Figure 4 – GP1272 charging characteristics for the constant voltage 13.65V (2.275 V/cell) (Example of the charging characteristics for the standby use of CSB VRLA GP series battery.)
Figure 5: Relation between battery temperature and charging voltage for standby use
Discharge
The battery capacity (Ah) is an integration of the discharge current I(t), and discharge time to the final discharge voltage:
Battery capacity (Ah) = ∫ I (t) dt
From the above equation, the variation of discharge time is dependent on the discharge current. The battery capacity also greatly depends on the discharge current.
For example, compare a 20 hour and a 1 hour rate:
For 20 hours, 0.05C (A) x 20 (h) = 1C (Ah)
For 1 hour, 0.6C (A) x 1 (h) = 0.6C (Ah)
This means that the capacity for the one hour rate is 60% less of the 20 hour rate. Evidently, increasing discharge current causes a decrease in the apparent Ah capacity. The final discharge voltage also varies depending on the discharge current.
The discharge capacity is affected by the battery temperature during discharge.
Generally, the capacity decreases when the battery temperature decreases during discharge.
Discharge characteristics are described in Figure 6, Figure 7, and Figure 8.
Discharge current and final discharge voltage
For the relation between discharge current and final discharge voltage, please refer to Table 2. The battery should never be discharged to less than the predetermined final discharge voltage. Otherwise, over discharging may result. Repeated over discharging may result in capacity failure, even with proper charging.
Discharge characteristics at various rates
Figures 6 shows the discharge performance at various rates for GP1272 and GP12400, respectively. Figure 9 shows the relation between the discharge current and time using this figure. Select the appropriate capacity for the VRLA battery. For the final discharge voltage, refer to Table 2.
Temperature and discharge capacity
Figure 8 shows the relation between temperature and discharge capacity. This figure shows the result of a charge at 25°C (77°F) and discharge at various temperatures. Avoid operation of the battery below -20°C (4°F) or beyond 50°C (122°F) since damage may occur even though the battery may still operate.
Figure 6: GP1272 discharge characteristics at various rates [25°C (77°F)]
Figure 7: GP12400 discharge characteristics at rates [25°C (77°F)]
Figure 8: Temperature and discharge capacity [25°C (77°F)]
Figure 9: Discharge current and discharge duration time period [25°C (77°F)]
Over-discharge
Compared to the alkaline battery, the VRLA battery is very sensitive to over-discharge. Over-discharge results in failure to recover normal capacity, reduced capacity, or shortened service life. Over-discharge also occurs by leaving the battery in a discharged state. The CSB VRLA Battery overcomes this problem. If our battery is over-discharged and left standing in a discharged state for several days, it can recover its original capacity when charged. However it is necessary to avoid over-discharge situations as much as possible.
Figure 10 shows an example of the charge characteristics after over-discharge and leaving the battery in a discharged state.
Precautions:
- The original capacity can be recovered after two or three consecutive over-discharges or leaving the battery in a discharged state. Beyond this limit, the battery may not recover to its original capacity.
- Always perform constant-voltage charging with a 2.45 V/cell with maximum current of 0.3CA. The charge voltage range between 2.275 V/cell may not be enough to recover to the capacity above. In this case, repeat charge and discharge two or three more times. Figure 10 shows an example of the charge characteristics after over-discharge and leaving the battery in a discharged state. As this figure shows, the charge current remains unchanged during the initial period of charge, this is not considered abnormal.
Figure 10: An example of the charging characteristics after over-discharge and leaving the battery in a discharged state.
Capacity Retention and Storage
Capacity Retention
When the charged battery is left standing for an extended period of time, its capacity gradually decreases and enters to a discharged state. The battery consumes the stored electrical energy without releasing it effectively to the circuits. This is called self-discharge. This disappearance of capacity is inevitable and will occur even if the battery is not being used. Self-discharge is caused by internal chemical and electrochemical reactions within the battery. Self-discharge for a lead acid battery is described below.
Chemical
Both (+) active mass (lead dioxide) and (-) active mass (sponge lead), are either decomposed or brought to gradual reaction with sulfuric acid in the electrolyte, which then changes to stable lead sulfate causing self-discharge.
Electrochemical
Impurities brought to the battery either from local cells or oxidation reduces both electrodes, causing self-discharge. The self-discharge quantity of the CSB battery is very small, 1/3 to 1/4 that of ordinary lead-acid batteries. This means that this battery has a superior capacity retention characteristic. Figure 11 shows capacity retention characteristics and storage guidelines.
Figure 11: Capacity retention characteristics and the supplementary charge and storage guidelines.
Storage
Lead-acid batteries previously were affected by long term storage after charging. CSB’s VRLA Battery, because of its Pb-Ca alloy offers longer extended storage than conventional batteries. Please see Figure 11.
During storage, carry out supplementary charging according to the cycle shown in Table 3. For supplementary charging after prolonged storage, either the constant-voltage charge with 2.45V/cell, or the constant-current charge with 0.05CA, is recommended. But, sometimes, one supplementary charge may not recover to 100% capacity. In such a case, it should be repeated until the capacity is recovered before storage.
Table 3: Storage temperature and recommended supplementary charge interval.
Open circuit voltage and residual capacity
Figure 12 show the relation between open circuit voltage and residual capacity.
Figure 12: Open circuit voltage characteristics
Service Life
Similar to other batteries, CSB’s VRLA Battery develops electrode deterioration after extended use. When the service limit is reached, the capacity cannot be recovered by charging. Depending on the charging method or service temperature, the battery may have a shorter life than a lead-acid battery with a large quantity of electrolyte.
The following factors are mainly responsible for shortening the service life of the battery:
(1) Discharge depth
Repetition of discharge with a large discharge quantity (that is, deep discharge), shortens the cycle life.
(2) Discharge current magnitude
After discharge with a small discharge quantity (that is, shallow discharge), and follow with a very large discharge current will shorten the service life.
(3) Charging current magnitude
An excessively large current generates gas in a quantity exceeding the recombination rate of the battery. This causes the internal pressure to rise and gas is expelled by the valve. Finally, the electrolyte is expended which requires particular attention during trickle or float charging.
(4) Overcharge quantity
When a battery is overcharged, its components (plates, retainer, etc.) will suffer from deterioration due to electrolytic oxidation. With both trickle and float charge, the overcharge quantity is a vital factor in determining battery life.
(5) Influence of ambient temperature
High ambient temperature accelerates deterioration of battery components. With constant-voltage charging, high ambient temperature allows unnecessary large quantities of charge current to flow, which results in a shorter service life. Charging at lower temperature, however, causes generation of H2 gas. This gas causes the internal pressure to increase or the electrolyte to decrease, and thereby shortens service life.
Cycle service life
Figure 13 shows the relationship between the discharge depth and number of discharge cycles. As the discharge depth increases during servicing, the number of service cycles decreases. When used with similar loads, the battery which is designed for expanded capacity will have a better service life.
Trickle (float) charging service life
Figure 14 shows the battery capacity and trickle (or float) charge service life. The dark shaded portion indicates the range of the service life characteristic.
General
Choose the appropriate charging method according to the application and conditions of CSB’s VRLA Battery to get full performance from the battery. Methods available are: semi-constant current charging method, constant current charging method, constant voltage charging method, and two-step constant voltage method. The semi-constant voltage method and constant voltage method are generally used for batteries with cycle servicing.
The constant voltage charging method is generally used for standby servicing (trickle or float). Also, the semi-constant current charging method is used for supplementary charging of the battery with extended storage period. Recently the two-step voltage charging method is being used for rapid charging of the VRLA battery. Please refer to Table 4 for an explanation of the charging methods and their features:
Table 4: Sealed lead-acid battery charging methods and features
Charging methods
(1) Semi-constant current charging method (simplified method)
This method, referred to as a simplified method, is easy to perform and is widely used for cycle service batteries. The charger consists of a transformer, diode and resistor. Impedance from these elements ensures charging without excessive changes in the charging current.
With this method, the battery voltage increases while the charging current decreases, as the charging proceeds. The problem with this method is that the charging current flows in a large quantity at the final stage and causes over charge. Care should be taken to avoid charging for more than the specified charge period.
Figure 15: Semi-constant current charging characteristics.
(2) Constant current charging method
This method consists of charging the battery with constant current. With this method the charging time and charging quantity can easily be calculated. To do so, an expensive circuit is necessary to obtain a highly accurate constant current. Consequently, this charging method is rarely used for general purposes.
Figure 16: Constant current charging characteristics.
(3) Constant voltage charging method (constant-current constant-voltage charging method)
This method consists of applying constant voltage to the battery with a constant voltage unit. This charging method utilizes a different voltage between its voltage and battery voltage. The charging current is initially large and decreases towards the end of charging. It is necessary to set the charging voltage according to battery charging and temperature characteristics. Inaccurate voltage causes an overcharge or an undercharge. Since there is a large current flow at the start, this method requires a large capacity charging unit which will be more expensive. Consequently the constant-current, constant-voltage charging method with limited initial current is widely used for cycle and standby use batteries.
Figure 17: Constant-voltage constant-current charging characteristic
(4) Two-step constant voltage charging method
This method uses two constant-voltage phases. The phase with high charging voltage setting is used initially. When the charge is nearly complete, and the battery charging voltage has risen to a specified value (with the charging current decreased), the second phase is used with lower charging voltage and current setting. This method enables rapid charging during cycle service, without the possibility of overcharge even after a long extended charge. This method also allows rapid charge in stand-by use.
Figure 18: Two-step constant voltage charging characteristic
Charging precautions
For cycle use
Cycle use requires charging to be completed within a short period. However, care should be taken when an individual is not familiar with the battery or charger. Particularly when applying a rapid charge, protective measures (incorporation of a backup timer, etc.) should be taken to prevent overcharge.
- Take safety precautions, such as an automatic cut off of charging upon completion; or preventing overcharge even after a long extended charging by controlling the charge current.
- The charging characteristic is affected by temperature. Use a temperature compensation circuit when charging is to be made at an ambient temperature of less than 5°C (41°F) or more than 35°C (95°F), and average temperature is more than 25oC (77oF).
- Contact CSB if rapid charging needs to be made within two or less hours.
For standby use
For standby use, please use a trickle or float charge. In either case, the battery is normally charged at a small current to compensate for the self-discharge of the battery. Supplying power from the battery is only used in emergencies such as a power failure, etc. This method requires a lot of time for charging, and the two-step constant-voltage charging method should be used when the battery’s capacity is to be recovered within a short period after discharge. Please check the following points when configuring a charger for standby battery use.
- Because the battery is charging continuously for a long period of time, even a slight fluctuation in the charging voltage results in a big difference in the expected service life of the battery. It is essential to ensure accurate control to minimize charging voltage fluctuations.
- The charging characteristic is affected by temperature. Use a temperature compensation circuit when charging is to be made at an ambient temperature of less than 5°C (41°F) or more than 35°C (95°F), and an average temperature above 25oC (77oF).
Scope of Application
The following describes precautions should to be observed when operating a CSB VRLA battery with a capacity of 4.5 to 100 Ah.
Precautions for Design of Power Supply Unit
Charging
A. For Standby Use (Trickle Charge or Float Charge)
- Charge the battery at a constant voltage of 2.275 V/cell (25°C or 77oF). When charging at an ambient temperature of less than 5°C (41°F) or more than 35°C (95°F), and average temperature above 25oC (77oF), it is necessary to adjust the charge voltage in ratio to the temperature. The temperature coefficient should be -3.3mV/°C cell.
- Initial charging current should be 0.3CA (where C is the nominal capacity value and A is amperes) or less.
- We recommend charging the battery at an ambient temperature between 5°C (41oF) and 35°C (95oF) to prevent any adverse effects on its effective life.
B. For cycle service
- Maintain a modified constant voltage or a constant voltage charge at a voltage of 2.45 V/cell (25°C or 77oF). When charging at an ambient temperature of less than 5°C (41°F) or more than 35°C (95°F), it is necessary to adjust the charge voltage in ratio of the temperature. The temperature coefficient should be -5mV/°C cell.
- Initial charging current should be 0.3CA (where C is the nominal capacity value and A is amperes) or less.
- To avoid overcharging, when charging is finished, we recommend charging to be stopped by using a timer or the constant voltage to be dropped to 2.275 V/cell (25°C or 77oF).
- We also recommend charging the battery at an ambient temperature between 5°C to 35°C to prevent any adverse effects on its effective life.
- If rapid charging is required, please contact us.
Discharge
- The continuous discharge and maximum discharge current (for 5 Seconds) should never exceed the values shown in the Specification List.
- Final discharge voltage and discharge current should be the same as shown in Table 5. Never discharge the battery until the voltage and current are less than the values shown in this table. Repeated over discharge will shorten the battery’s life.
- After discharging, immediately recharge the battery. Never leave it discharged. The capacity to hold a charge may not be recovered if the battery is left discharged for a long period.
Table 5:
Installation and Connection
- Secure the battery firmly to protect it from excessive vibration or impact.
- When placing the battery in equipment, keep it away from a heat generating source (e.g., a transformer) and install it in an upright position and as low as possible with proper ventilation.
- The battery may produce a combustible gas. Avoid installation in closed compartment or near sparks (i. e., near a switch or fuse).
- Using vinyl chloride sheathed wire or a vinyl chloride sheet may crack the battery container and cover. Either keep it away from the battery or use a non-plasticizing vinyl chloride material.
- Never bend the terminal nor solder directly to it.
- Avoid using the battery in the following places:
- Areas exposed to direct sunlight
- Areas where there is excessive radioactivity, infrared radiation, or ultraviolet radiation
- Areas filled with organic solvent, vapor, dust, or corrosive gases
- Areas of abnormal vibration
- When connecting the battery to a charger or a load, keep the circuit switch OFF and connect the battery’s positive (+) terminal to the positive (+) pole of the charger or the load and the battery’s negative (-) terminal to the negative (-) pole of the charger or the load.
- Never use the batteries or different capacities, batteries of different performances, or new and old batteries together.
- Do not series connect more than 32 pcs of battery in a single string or parallel connect more than 4 strings. If more batteries are needed for series/parallel application as stated above, please contact us.
General Handling Precautions
Before Use
A. Storage and supplementary charging
- During storage, the capacity of the battery decreases due to self-discharging. Store the battery in a cool dry place. Where the monthly average temperature exceeds 25°C (77oF) (below 30°C or 86oF), carry out supplementary charging every 3 months. Where the monthly average temperature falls below 25°C (77oF), carry out supplementary charging every 6 months.
- When using a stored battery, always carry out supplementary charging before use.
- For supplementary charging, please refer to Table 6.
B. Transporting
- When transporting the battery, never vibrate or impact it excessively.
- We recommend transporting the battery in an upright position.
- When transporting a battery connected to equipment, secure it firmly and keep the circuit open.
Daily Inspection and Servicing
When the following abnormalities are observed, discover the cause and replace any defective batteries:
- Any voltage abnormalities
- Any physical defects (e.g., a cracked or deformed container cover)
- Any electrolyte leakage
- Any abnormal heat generation
Clean any dust contamination with a wet cloth. Never use organic solvents (e.g., gasoline or thinners), and never use chemicals on the battery, for any other purpose. Otherwise the container or cover may develop cracks. If you need to use any chemical on the battery, please contact CSB for more information.
When installing the battery as an emergency power supply for fire-fighting equipment, inspect it according to the Fire-fighting Equipment Poser Supply Inspection Standard or Inspection Procedure.
Other Precautions
- The battery may produce a combustible gas. To prevent a rupture, never place the battery near a fire.
- Never short the terminals. Shorting may cause the battery to burn.
- Never disassemble or reassemble the battery.
- Never attempt to reverse charge the battery. This not only fails to charge the battery, but also diminishes its performance and may cause the electrolyte to leak.
Life of the Battery
Generally the battery’s effective life is 3 to 5 years for standby use and 260 cycles (100% depth of discharge) or more for cycle use. The effective life may be shortened when the proper conditions are not maintained (i.e., for charging, discharging, working temperature, and storage). In order to ensure that battery normal performance is maintained, please replace battery unit prior to expected end-of-life date.
For Example: GP/HC/HR/EVX series battery should be replaced according to the average operating temperature. Please see below for recommended change period:
- Average Operating Temperature Change Period
- 25°C or 77°F (Room temperature) within 3 years
- 30°C or 86°F within 2.5 years
- 40°C or 104°F within 1.4 years
Tightening Torque Specification
Valve Regulated Lead Acid Batteries, commonly known as VRLA
In order to ensure the safe operation of our VRLA batteries, correct and accurate procedures must be employed.
All individuals who work with VRLA must be made aware of the Dangers, Warnings, Attentions and Suggestions, for proper use of our batteries in order to avoid accidents and injuries.
Please read this document thoroughly and retain it for reference in case it is needed in an emergency situation. Our VRLA batteries contain high density energy. Incorrect operation can cause explosion, leaking acid, as well as extreme heat. Those situations can cause harm to an individual who has not read and understood this document.
VRLA Battery Dangers
Means extreme danger, will cause a serious injury, even death under improper usage.
- Do not seal the battery inside of any machinery. Please make sure that the battery is well ventilated. Placing the battery in an hermetically sealed space can cause the battery to explode causing damage to the machinery or extreme personal injury.
- Do not place the battery in a hermetically sealed space that is closed or close to any source of heat or flame. This could cause the battery to ignite or even explode.
- All connection cables should be well insulated and not able to short electrically. If the cables do cause an electrical short, that may cause smoke or the battery to cause a large destructive fire.
- Do not use any metal such as steel wire brush to connect or clean the terminals. Be careful not to drop any personal jewellery, hair pins or any other metallic objects when servicing the batteries. Metal objects can cause an electrical short which can be a source of leaking, heat or a destructive fire.
VRLA Battery Warnings
Means urgent danger, causing the possibility of death or serious injury is less likely; can possibly cause light injury or facility damage under faulty operation.
- Always use the proper charger and the charging regulations set by CSB. Not following our guidelines and procedures, or using non-approved charging procedures, can cause the battery to leak acid, heat up, or cause a destructive fire.
- When our batteries are used for medical applications, please be aware of the possibility that the battery could fail. Back-up units should be in place to prevent injuries.
- The container cannot come in contact with metal products. Please use insulated material that has acid and heat resisting characteristics to be the battery container. Not using insulated materials may cause fire or an explosion by leaking.
- Do not install batteries close to any location where a spark may occur such as a switch or a fuse. Sparks may cause fire or an explosion.
- Always wear insulated gloves during any battery servicing activities, otherwise you could get an electrical shock.
- Do not install a battery in a high traffic area without adequately protecting the battery. Not doing so could cause an electrical shock or fire in case the battery is disturbed or dislodged.
- Do not burn the battery or throw it into a fire. Doing so may cause the battery to explode and toxic gas to be released.
- Do not disassemble, reassemble or destroy the battery. Doing so could cause the acid inside the battery to leak and cause severe burns or other accidents.
- Do not use any dry fabric or other materials to clean the battery that could cause static electricity. Always use a damp cloth that has had the moisture wrung out of it.
- The battery should be replaced before the expiration date. Upon installation a log of expiration dates should be kept in a handbook or on front of the machinery.
- When the battery’s performance has only 50% left at 25°C, the battery should be replaced. The battery’s life will curtail one half with a raise of each 10°C in temperature. If the discharging current is higher than 0.25CA, the battery’s life will be shorted.
- When the battery approaches the end of its life, its performance will decrease very fast. The internal exhausted electrolyte and the corrosion of the positive plate may cause a failure. If the battery continues in operation under these conditions, there could be extreme heat, leaking of even explosion.
- There is sulfuric acid inside of the battery. Please use water if skin or clothes become contaminated by the acid. If acid gets into your eyes, use ample clean fresh water to flush your eyes and seek immediate medical attention.
Attention
Means ordinary danger, the chance for serious injury is less. However, light injury or facility damage could be possible with faulty operation.
- The standard operating temperature for our batteries is 5-35°C (41-95°F). Usage outside this range will cause damage to the battery.
- Our batteries cannot be used beside any heat source such as a transformer.
- Do not let water or sea water wet or soak our batteries.
- Do not leave one of our batteries inside an automobile or any other place with strong sunlight.
- Do not place our batteries in areas where there is a lot of powder residue. The powder could cause a short in the battery.
- When using our batteries in a series, connections should be made between the batteries before charging or placing the series under a load. Remember, the positive terminal of the battery must connect to the positive side of the charger or the load. The negative terminal of the battery must connect to the negative side of the charge or load. Otherwise an explosion may occur causing personnel or equipment damage.
- Be careful when handling batteries or taking them out of their racks or storage units. Please wear protective footwear when handling our batteries.
- When unpacking CSB VRLA batteries from their shipping container, be careful when removing them so as not to drop them. If dropped, their container could crack and cause sulfuric acid to leak out.
- Placing CSB VRLA batteries upside down could cause sulfuric acid to leak out.
- Do not grab the battery terminal or cable to shift its position. Doing so could cause damage to the battery or electrical shock.
- Be careful not to let a battery fall. A dropped battery could cause a crack in its container and sulfuric acid could leak out.
- Some of the models of our batteries are very heavy, please carry or transport them correctly to prevent an occupational injury.
- Please do not use any type of organic solvent to clean our batteries, and never use chemicals on the battery, for any other purpose. Otherwise the container or cover may develop cracks. If you need to use any chemical on the battery, please contact CSB for more information.
- Always release any static electricity buildup on your body before touching or servicing our batteries to prevent sparks.
- Do not use plastic sheets to cover our batteries. Removing a plastic sheet could cause a static electricity build up and sparks could occur.
- Please use the connection screws that CSB provides to avoid possible sparks.
- Please use insulated materials to cover the terminal and connector in order to avoid possible sparks and shorts.
- For electric mobility, bikes or lawn mowers where the equipment might have vibrations during usage, please be sure that our batteries are firmly anchored to avoid damage or shorting of the terminals.
- Please terminate all switches between the battery, load or charger before making any connections.
- Do not use the battery out of its application usage range. Doing so may cause leaking, heat or fire.
- If there is an observed unusual situation of charging voltage or discharge characteristics, please replace the battery.
- Please follow the list below to ensure proper battery safety. A failure to do so could cause a battery to leak, radiate heat or cause an explosion.
- Ensure that there is a correct connection between the battery and the charger; do not reverse the terminal connection.
- Do not weld directly on the terminal.
- Do not mix different brands, models, or date codes of batteries.
- Do not dismantle any part of the battery assembly.
- Do not throw the battery or hit it with any type of instrument.
- Do not charge the battery over the recommended charging time, otherwise the battery could leak, radiate heat, or even explode.
- Our batteries should be placed in a safe place out of reach from children. If our batteries are the power source for a toy that a child uses, they should be supervised and instructed in the proper operation, charging and usage of the battery.
- CSB VRLA batteries are constructed with a negative plate absorption system. This means the oxygen from the positive plate will be absorbed by the negative plate. In the first 12 months of usage, the float charge voltage may be out of the standard value. This is normal for this type of battery.
- If there is an unexpected electrolyte (sulfuric acid) spill or leakage, immediately neutralize the spill with sodium carbonate then wipe it up. If the spill is not neutralized, there could be corrosion on the floor or equipment.
- If a battery catches on fire, please use a proper powder charged fire extinguisher. Do not ever use a water based fire extinguisher.
- After an earthquake, please check the tightness or each connection to avoid spark.
- After an earthquake, please inspect each battery container to make sure that there are no cracks or leaks. If you notice an unusual situation, immediately terminate the operation of the equipment to ensure the safety of all personnel and equipment.
VRLA Battery Suggestions
Means unsuitable usage will affect the quality and performance of the battery.
- Please make sure that the battery is properly stabilized. A strong impact can affect the battery’s performance.
- Battery life should be verified by actual loading conditions as well as by different charging/discharging conditions.
- Battery installation should only be done by trained and qualified personnel.
- For the initial use or if a battery has been stored for a long period of time, please recharge the battery fully before putting it into service. A battery’s performance will reduce automatically by self discharge.
- If a battery is stored for more than 3 months, we suggest a recharge before the battery is put into service. When storing a VRLA battery, a recharge should be repeated every 3 months.
- Do not let a VRLA battery discharge to a voltage lower than its suggested final voltage. Doing so will affect the battery’s performance.
- Do not over-discharge a VRLA battery. After discharge immediately recharge a battery.
- Use the right charging/discharging settings to ensure the battery’s quality and performance.
- Shut down the main switch of any equipment that the VRLA battery is connected to after usage otherwise an over discharge state may occur.
- If the equipment will not be in use for a long period, please remove the battery from the equipment and store in a dry area.
- If the environmental temperature increases by 10°C, the recharging time must be decreased by one half. If a battery is stored under 35°C, it should be recharged every 11/2 months instead of every 3 months.
- If a battery is stored for more than a year without any recharging activity, the battery’s life will be worth less than the original specifications.
- VRLA battery inventories should be rotated to ensure that batteries pulled out of storage are fresh and ready to use. After a long period of storage, without a regular recharging program, a battery’s performance may not come back to specified capacity.
VRLA Battery Safety Concerns
Maintenance and servicing of a VRLA battery should only be performed and supervised by personnel knowledgeable of lead acid batteries. Personnel should also be knowledgeable of personal and equipment safety precautions. Keep unauthorized personnel away from the batteries during maintenance activities.
VRLA Battery Electrical Hazards
Battery systems present a risk of electrical shock and high current short circuits. The following precautions should be observed when maintaining VRLA batteries:
- Remove all personal metal objects (watches, rings, etc.)
- Use insulated tools.
- Wear full eye protection and rubber gloves.
- Observe circuit polarities.
- Do not make or break live circuits.
- Prior to handling batteries on a metal rack, assure the battery is not inadvertently grounded by observing the ground fault detector indicator. In its absence, measure the voltage between the battery and the rack. It should be zero. If not, determine the cause and correct prior to proceeding.
- Do not lay metal tools and hardware on top of the batteries.
- As appropriate, use an insulating blanket to cover exposed portions of the battery system when performing extended maintenance that could result in personal or equipment contact with the energized conductors.
Certain types of rectifier circuits used in charging the VRLA battery may not include a line isolating transformer. In these cases extreme caution should be exercised when maintaining and collecting data on the battery system.
VRLA batteries are sometimes enclosed in cabinets with very limited access. Again, extreme caution must be exercised when maintaining and collecting measurements on the battery system.
VRLA Battery Recycling & Disposal
Lead acid batteries are to be recycled. Batteries contain lead and dilute sulfuric acid. Dispose of the battery in accordance with federal, state and local regulations. Do not dispose of the battery in a landfill, lake or other unauthorized location.
VRLA Battery Chemical Hazards
Any gelled or liquid emissions from a VRLA battery is electrolyte which contains dilute sulfuric acid that is harmful to the skin and eyes. The electrolyte is also electrically conductive and corrosive.
If the electrolyte contacts the skin, wash the area immediately and thoroughly with water. If electrolyte enters the eyes, wash your eyes thoroughly for a 10 minute period with clear water or a special neutralizing eye wash solution and seek immediate medial attention.
Neutralize any spilled electrolyte with the special solution contained in a “spill kit” or with a solution of 1 pound of bicarbonate of soda to 1 gallon of water.
Fire, Explosion and Heat Hazards
Lead acid batteries can contain an explosive mixture of hydrogen gas which can vent under overcharging conditions.
Do not smoke or introduce sparks in the vicinity of the battery.
Prior to handling the battery, touch a grounded metal object, such as the rack, to dissipate any static charge that may have developed on your body.
Do not charge batteries in a sealed container. The individual batteries should have 5 to 10 millimeters of space between them to allow for proper cooling. If contained, assure the container, cabinet or room has adequate ventilation to prevent an accumulation of potentially vented gas.
VRLA Battery Warnings
Do not attempt to remove the vents (valves) from CSB’s VRLA battery or add water. This procedure presents a safety hazard and voids the warranty.
Preparation for VRLA Battery Periodic Inspections & Maintenance
For optimum reliability, it is recommended that the battery system be monitored quarterly. If the battery system incorporates an automatic monitoring system to gather the electrical and environmental data, the quarterly checks are limited to the evaluation of the recorded data and a visual inspection of the battery.
In general the types of inspections to be made during periodic maintenance include:
- Visual battery inspection
- Battery system capacity test
- Battery system voltage inspection
- Ambient temperature
- Individual battery float voltage inspection
- High rate load test
- Electrical resistance and tightness of inter-unit connections
A test of the individual unit resistance, impedance or conductance, while optional, is also recommended on a periodic basis. This data and its trends can be a valuable aid in troubleshooting the system and predicting the need for a system capacity test.
Prior to starting the periodic maintenance activity assure that all the required maintenance tools and equipment is available and functional. Notify anyone who will be affected by the intended maintenance or troubleshooting activity.
All, all units in the battery should be numbered so as to facilitate the recording and analysis of data unique to each unit.
Tools and Equipment Required for Inspections & Maintenance
At a minimum, the following tools and equipment are required to maintain and troubleshoot CSB’s VRLA Battery:
- Digital voltmeter
- Current clamp
- Impedance tester
- System load bank
- Recorder
- Insulated socket wrenches
- Insulated box end wrenches
- Torque wrench
- Screw driver
- Rubber gloves
- Face shield or goggles
- Portable eyewash
- Fire extinguisher
Quarterly VRLA Battery Inspection
The following inspection should be completed quarterly.
- Assure the battery room is clean, free of debris and with proper lighting.
- Assure that all facility safety equipment is available and functional.
- Measure and record the air temperature within the battery room.
- Visually inspect the battery for:
- cleanliness
- terminal damage or evidence of heating
- container or cover damage
- Measure the DC voltage from each polarity of the battery to ground and detect any ground faults.
- Measure and record the individual unit DC float charging voltage, and current.
- Measure and record the system equalization voltage, and current.
- Measure and record the temperature of the battery cabinet inspections.
Semiannual VRLA Battery Inspection
The following inspection should be completed semiannually.
- Repeat the quarterly inspection.
- Randomly measure and record the resistance/conductance of the individual units to trend the condition of the individual units over time and to detect dramatic differences between individual units and the norm.
Annual VRLA Battery Inspection
The following inspection should be completed annually.
- Repeat the semiannual inspection.
- Re-torque all of the inter-unit connecting hardware. This can be omitted if the connection resistance is measured and found to have not increased more than 20% from the value recorded at installation.
Biannual VRLA Battery Inspection
The battery should be capacity tested every two years at the service load or at the battery rating related to the service requirements. Ideally, this will be the same rate at which it was acceptable when tests were run upon installation.
Quarterly VRLA Battery Inspection
The data accumulated during the periodic maintenance activities should be recorded on a form. Following is an explanation of how the data would be interpreted and the corrective action to be taken. However, it must be recognized that this explanation is not all inclusive and the analysis and corrective decision must be made by personnel familiar with VRLA batteries and their operation and failure modes.
The following inspections, symptoms and solutions are provided for reference. The actual judgments should be performed by CSB’s Quality Assurance Department.
For assurance of the optimum reliability it is necessary to perform the recommended periodic maintenance. The recommended inspections should be performed at least on a quarterly basis.
The recommended periodic inspections can be performed either manually or via automated monitoring systems.
The recommended periodic inspections are designed to determine the gradual degradation of the system’s capacity and to detect any abnormal system or individual battery condition which could impact system reliability.
VRLA Battery Visual Inspection
VRLA Battery Capacity Test Results
VRLA Battery DC Voltage Inspections
VRLA Battery Float Charging Current Inspections
VRLA Battery Temperature Inspections
VRLA Battery High Rate 10 Second Load Test
VRLA Battery Connection Hardware Resistance / Tightness Inspection
VRLA Battery AC Ripple Voltage Inspections
Preparation for VRLA Battery Periodic Inspections & Maintenance
For optimum reliability, it is recommended that the battery system be monitored quarterly. If the battery system incorporates an automatic monitoring system to gather the electrical and environmental data, the quarterly checks are limited to the evaluation of the recorded data and a visual inspection of the battery.
In general the types of inspections to be made during periodic maintenance include:
- Visual battery inspection
- Battery system capacity test
- Battery system voltage inspection
- Ambient temperature
- Individual battery float voltage inspection
- High rate load test
- Electrical resistance and tightness of inter-unit connections
A test of the individual unit resistance, impedance or conductance, while optional, is also recommended on a periodic basis. This data and its trends can be a valuable aid in troubleshooting the system and predicting the need for a system capacity test.
Prior to starting the periodic maintenance activity assure that all the required maintenance tools and equipment is available and functional. Notify anyone who will be affected by the intended maintenance or troubleshooting activity.
All, all units in the battery should be numbered so as to facilitate the recording and analysis of data unique to each unit.
Tools and Equipment Required for Inspections & Maintenance
At a minimum, the following tools and equipment are required to maintain and troubleshoot CSB’s VRLA Battery:
- Digital voltmeter
- Current clamp
- Impedance tester
- System load bank
- Recorder
- Insulated socket wrenches
- Insulated box end wrenches
- Torque wrench
- Screw driver
- Rubber gloves
- Face shield or goggles
- Portable eyewash
- Fire extinguisher
Quarterly VRLA Battery Inspection
The following inspection should be completed quarterly.
- Assure the battery room is clean, free of debris and with proper lighting.
- Assure that all facility safety equipment is available and functional.
- Measure and record the air temperature within the battery room.
- Visually inspect the battery for:
- cleanliness
- terminal damage or evidence of heating
- container or cover damage
- Measure the DC voltage from each polarity of the battery to ground and detect any ground faults.
- Measure and record the individual unit DC float charging voltage, and current.
- Measure and record the system equalization voltage, and current.
- Measure and record the temperature of the battery cabinet inspections.
Semiannual VRLA Battery Inspection
The following inspection should be completed semiannually.
- Repeat the quarterly inspection.
- Randomly measure and record the resistance/conductance of the individual units to trend the condition of the individual units over time and to detect dramatic differences between individual units and the norm.
Annual VRLA Battery Inspection
The following inspection should be completed annually.
- Repeat the semiannual inspection.
- Re-torque all of the inter-unit connecting hardware. This can be omitted if the connection resistance is measured and found to have not increased more than 20% from the value recorded at installation.
Biannual VRLA Battery Inspection
The battery should be capacity tested every two years at the service load or at the battery rating related to the service requirements. Ideally, this will be the same rate at which it was acceptable when tests were run upon installation.
Quarterly VRLA Battery Inspection
The data accumulated during the periodic maintenance activities should be recorded on a form. Following is an explanation of how the data would be interpreted and the corrective action to be taken. However, it must be recognized that this explanation is not all inclusive and the analysis and corrective decision must be made by personnel familiar with VRLA batteries and their operation and failure modes.