Gel AGM Flooded

Types of Batteries:

Types of Stationary Lead Acid Batteries

Flooded Batteries Maintenance Free VRLA Batteries

Conventional tubular Flat plate AGM VRLA

Low maintenance

Conventional tubular lead acid Batteries

Flat plate AGM VRLA Batteries

Flat plate Hybrid VRLA BatteriesLow maintenance

tubular lead acid Batteries

Batteries

Tubular GEL VRLA Batteries

WHAT IS A FLOODED BATTERY?

A flooded battery is a lead acid electricstorage battery that:

1. Can be open vented

2. Can use high antimony, lowti l i t l llantimony or calcium metal alloys

or a combination of calcium andlow antimony (hybrid.)

3. Requires maintenance in cyclicapplications

4. Its entire electrolyte volume is freeto move within the cell and escapeof hydrogen and oxygen gassesnormally lost during charging.

5. It is spill able, and therefore canonly be operated in an up rightposition.

Flooded Electrolyte Advantages:

1. Lowest initial cost2. Suitable for low & medium rate applications.3 Water can be added 3. Water can be added 4. More tolerant of improper recharge voltages.5. Certain designs are good for deep cyclic applications.

Flooded Electrolyte disadvantages:

1. Spill able.2. Operates upright only.3. Shorter shelf life.4. Fewer shipping options.5. Cannot be installed near sensitive electronic

equipment.6. Watering will be required .6. Watering will be required .7. Requires high levels of maintenance & safety practices.

WHAT IS AGM BATTERY ?

Vent PlugReliable Valve Operation Flame retardant porous disc Provides safety

Terminal Post Consistent quality weld Provides leak free Operation Improves high rate performance safety

Moss Shield Prevents ShorteningAllows uniform ElectrolyteDistributionP id i idit

high rate performance

Provides rigidity

Compression Pad Provides Uniform Compression at desired pressure

Positive Electrode Unique griddesign & proprietry lead alloyreduces plate growthProprietary paste formulaprovides excellent deep cycling Compression at desired pressure

Provides rigidity Prevents bulgingy

capability & long lifeProcess Provides good bonding

‘U’ Wrap AGM Prevents plates from shorting Extra thick and absorbent mat for long life

Ribbed Jar Provides extra strength Better heat dissipation Tolerant against thermal runway g

Provides uniform electrolyte distribution

1. It is sealed using special pressure valves and should never be opened

2. Typically uses calcium/Calcium metal alloys

3. It is completely maintenance free.3. t is completely maintenance f ee.

4. It’s entire electrolyte absorbed in separators consisting of sponge-like mass of matted glass fibers

5. Uses a recombination reaction to prevent the escape of hydrogen andoxygen gasses normally lost in a flooded lead acid battery duringcharging.

6. It is non-spill able , and therefore can be operated in virtually anyposition.

Advantages of AGM battery

1. Totally maintenance free

2. Spill proof/ leak proof

3. No corrosion

4. Lower cost than gel batteries.

5. Compatible with sensitive electronic equipment.

6. Very low to no gassing (unless overcharged).

7. Excellent for starting & stationary applications.

8. Superior for shorter duration /high rates of discharge.8. Superior for shorter duration /high rates of discharge.

9. Superior shelf life.

10. Superior recharge ability (from 0% to 90% in 6 - 8hours).

11. Rugged & vibrant resistant.

Disadvantages of AGM batteryg f y

1. Shorter cycle life than gel in very deep cycleapplications.applications.

2. Automatic temperature sensing , voltage regulatedcharges must be used.

3. Water cannot be replenished if continuallyovercharged.

4. Charge voltage must be limited (2.35V maximumper cell at 25°C /77°F ).

WHAT IS GEL VRLA BATTERY?

Sl.No Description NED Specification

Positive

Pressure die casted Tubular non ovengauntlet plates consisting of lead calcium

65

1 Positive Plate alloy optimized for high corrosion

resistance and for reducing shedding athigh temperature cyclic applications.

N ti Flat grid plates consisting of lead calcium2 Negative

Plate

g p g falloy and proprietary paste to operate atPSOC conditions.

3 SeparatorPolymer separator for electricalseparation of positive and negative plates

13 Separator separation of positive and negative plates

and optimized for low internal resistance.

4 Container & Cover FR grade PPCP for strength and durability

5 Terminals High conductivity brass inserts for easyand safe bolted assembly.

6 Valves

Vent assembly releases gas in case ofexcess pressure and protect the cells

3 6 Valves during abnormal charging conditions fromsafety point of view.2

43

1. It is sealed using special pressure valves and should never be opened

2. Typically uses calcium / Calcium metal alloys

3. With proper operating conditions is completely maintenance-free

4. Uses gelled electrolyte

5 U bi ti ti t t th f h d d5. Uses a recombination reaction to prevent the escape of hydrogen andoxygen gasses normally lost in a flooded lead-acid battery duringcharging.

6. It is non-spill able and therefore can be operated in virtually anyposition.

1. Totally maintenance free

2 Spill proof / leak proof

Advantages of Gelled Electrolyte:

2. Spill proof / leak proof

3. No corrosion

4. Superior for deep cycle applications.

5. Suitable for low & medium rate of discharge applications.

6. Very low to no gassing ( unless overcharged)

7. Compatible with sensitive electronic equipment

8. Superior shelf life

9. Superior recharge ability (from 0% to 90% in 6-8 hours).

10. Rugged & vibrant resistant.

11. Lowest cost per month ( cost/month of life)

12. Lowest cost per cycle ( cost / life cycle) – up to 12% more cycles than advancedAGM batteries when discharged capacity exceeds 80%.

13. Up to 3 times the cycling ability of standard AGM when discharge capacityexceeds 50% at high temperatures.

Higher initial cost.

Gelled Electrolyte disadvantages:

Heavier weight.

Water cannot be replenished if continuallyovercharged.

Automatic temperature sensing, voltage regulatedchargers must be used & charge voltage must bechargers must be used & charge voltage must belimited (2.35V maximum per cell at 25°C/ 77°F).

S No Feature VRLA AGM Tubular Flooded Tubular Gel VRLA

COMPARISON OF BATTERIES BASED ON DIFFERENT TECHNOLOGIES

S.No Feature VRLA AGM Tubular Flooded Tubular Gel VRLA

1 Gassing/FumingNo Gassing/Fuming

can be installed anywhere

High Gassing/fuming separate battery room with exhaust system is

essential

No Gassing/Fuming can be installed anywhere

2Topping up of

electrolyte

No topping-up required normally Topping up required

frequently No topping-up required

normally

3Space

requirement Small cell Size,

Low Space Requirement

Large cell Size, Large Space Requirement

Small cell Size, Low Space Requirement

V ti l t ki l 4 Stacking Horizontal or

Vertical

Vertical stacking only Tier Stacking is not

practical for long life.Horizontal or Vertical

5Transportation

in charged Easy Troublesome(enough protection to be made) Easy

Condition protection to be made)

6

Self dischargeduring storage at

an average Temperature of

50% self discharge in 6 months.

Recovery Easy.

Self discharge is very high. Long duration

storage not recommended. Recovery

50% self discharge in 1 year. Recovery Easy.

35° C difficult.

Reference: Evaluation of different battery technologies used in Indian telecom network by TEC


7 Cyclic life to 80% DOD

1000-1200 cycles at an average

temperature of 27°C in normal

environmental

1200-1500 cycles @ 27˚C Depends on

operating conditions & maintenance

1600-1800 cycles at an average temperature of

27°C.environmental conditions

maintenance

8 Float Life at 27°C 6-8 years 8-10 years 8-12 years

High 9

High Temperature Performance

Average Good Good

10Low

TemperaturePerformance

Good Poor GoodPerformance

11 Stratification Negligible no boost charging required

Prominent requires frequent boost charging

for prevention

Negligible no boost charging required

12 End cell 1 75V/ ll 1 85V/ ll 1 75V/ ll12 End cell Voltage 1.75V/cell 1.85V/cell 1.75V/cell

13

Capacity at very lower

rate of Discharge

Average Good Good

Discharge



14 Deep Discharge Recovery

Average after 4 to 5 Charge/Discharge

Cycles

Poor Hard sulphation prevents recovery

Average after 4 to 5 Charge/Discharge Cycles

15 Charge Excellent 6 to 8 H f 90% Poor 12 to 14 Hours for Slightly poor 8 to 10 15 Charge

efficiency Hours for 90% recovery

Poor 12 to 14 Hours for 90% recovery

Slightly poor 8 to 10 hours for 90% recovery.

16 Undercharged performance Average Poor Good

17 Over Charging Poor Good Good

Performance18

funder partial

state of chargeAverage Poor Good

19 Charging Requirement

Constant voltage charging for SMPS

Power plants

Periodical boost charging at 2.7 V/cell

essential

Constant voltage charging for SMPS

power PlantsPower plants essential power Plants

20 Thermal runaway Sensitive Robust Robust

21 Risk of internal h t i iti Remote High due to active

t i l h ddi Remoteshort circuiting material shedding


S.No Feature VRLA AGM Tubular Flooded Tubular Gel VRLAS.No Feature VRLA AGM Tubular Flooded Tubular Gel VRLA

22 Internal resistance

Very low Ideal for shortduration application

Very high suitable for low & medium rate of discharge applications

Higher because of Geland Suitable formedium rate ofapplications

23 Design

Flat plate used withAGM separator,suitable for high rateof discharge with

d t lif

Tubular positive & flatnegative plates are usedwith liquid electrolyte,suitable for low, medium

t li ti

Tubular positive & flatnegative plates,electrolyte is in theform of GEL, suitablefor low & medium ratemoderate life rate applications fapplications.

24 CostInitial cost is low.However cost per cyclei hi h id

Initial cost is moderate & cost per cycle is

medium. However it depends upon the

Initial cost is higher.However cost per cyclei lis on higher side depends upon the

operating conditions & maintenance

is low.

25 Water No addition of water

Frequency increasesdramatically with agedue to antimony No addition of water25 Addition No addition of water due to antimonycontamination ofnegative plate

No addition of water


PERFORMANCE CHARACTERISTICS

1. Recommended charging methods

S. No Type of battery

Float Applications @ 27°C Cyclic applications @ 27°C

2V cell 48VCell

Max cur.

Limit2V cell 48V

cell

Max cur.

LimitLimit Limit

1. Flooded tubular 2.23-2.25 53.52-54.00

0.1C10t

2.4-2.5 57.60-60.0

0.1C10to

2. AGM VRLA 2.25-2.27 54.0-54.48 2.30-2.35 55.20-56.4to

0.25C10

to 0.25C103. Tubular GEL 2.25-2.27 54.0-54.48 2.30-2.35 55.20-56.4

4. Hybrid VRLA 2.25-2.27 54.0-54.48 2.30-2.35 55.20-56.4

Initial performance

120

Initial performance

100

110

city

80

90

% o

f C

apac

Tubular Flooded

Tubular GEL

70

80% Tubular GEL

AGM

60

0 25 50 75 100No Of cycleso O cyc es

˚

10

Float service life @ 27˚C

789

456

108

10

Year

s

123

0Flooded AGM Gel

Batery Typey yp

Flooded: ZENITH AGM: ML Gel: MQ

80% DOD at 27˚C

1800

80% DOD at 27 C

1200

1400

1600 1800

es

600

800

1000 1200

1000

No

of c

ycle

200

400

600N

0Flooded AGM Gel

Battery type y yp


Cyclic life @50% DOD at 27˚C

3000

2000

2500 3000

3000

s

1000

1500 1800

of

Cycl

es

500

1000

No

0Flooded AGM Gel

Battery TypeBattery Type


Cyclic Life @ 20% DOD at 27˚C

4500

5000

3000

3500

4000 5000

4000

5000

cles

2000

2500

3000

No

of C

yc

500

1000

1500

0Flooded AGM Gel

Battery Typey yp


Recharge time at 60% DOD @ 27˚C

7

8 8 8

5

6

7

6

s

3

4

Hou

rs

0

1

2

0Flooded AGM Gel

Type of Battery


Recommended operating Temperature

S.No Battery Type Operating Temperature RemarksWhen Temperature

Recommended operating Temperature

1 Flooded 20°C to 55°CWhen Temperature

increases above 35˚C maintenance increases

2 G 0°C 30°CAbove 35°C life of the

b i d d 2 AGM 0°C to 30°C battery is reduced drastically

3 Hybrid 0°C to 40°CAbove 40°C life of the

battery is reduced y ydrastically

4 Tubular -20°C to +55°CSuitable for cyclic

applications @ high temperatures temperatures

Self Discharge:

Th lf di h t ill f ti f bi t tThe self discharge rate will vary as a function of ambient storagetemperature

Shelf life:

When lead acid battery of any type are stored for extended periods oftime, lead sulphate is for extended periods of time, lead sulphate isformed on negative plates of batteries this phenomenon is referred to as“sulphation”. Since the lead sulphate acts as an insulator, it hasdetrimental effect on charge acceptance. The more advanced thesulphation, the lower the charge acceptance

Shelf life at various temperatures

S.No Temperature RangeMonths

Flooded AGM GELFlooded AGM GEL1 0°C to 20°C 6 12 24

2 21°C to 30°C 3 6 12

3 31°C to 40°C 2 4 6

4 41°C to 50°C 1 2 3

Types of Lead Acid Batteries & Positioning Chart

Cost : Price per Ah per cycle @ 40˚Ccles p p y @

@ 2000 US$.

Backup : Initial Back up@ C/6 LoadAfter charging for 8 Hours @ 2.30/ ll d l f 7

No

of C

ycV/cell End Voltage of 47V

No. of Cycles: Cyclic Life @ 50% DOD

ML: Max Life “ AGM VRLA”.

MQ M Q li “T b l G l VRLA”

Z: ZENITH “Flooded LMLA”

MQ: Max Qualita “Tubular Gel VRLA”

rs.)

Temperature (˚C)Cost Rs. / Cycle

k-up

tim

e (H

rB

ack

Documents

Gel AGM Flooded