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IEC 60896-22
The Technical Requirements for Stationary VRLA Batteries
Herbert Giess - Mark Kniveton
Oerlikon Stationary Batteries Ltd. - British Telecom plc, Network Power & Cooling Unit
CH4147Aesch, Domacherstrasse 110, Switzerland - Bournemouth, BH1 2NR, 18-20 Bath Road, England

h.giess@accnoerlikon.com - mark.kniveton@bt.com

Abstract:
The elaboration of the new twin International Standard for
Stationary Lead Acid Batteries of the VRLA type, the Standard
IEC 60896-21 Method8 of Test and IEC 60896-22 Requirements
is nearing completion with only editorial issues outstanding.

These two standards will allow a transparent and user

oriented quantification of W U A battery behavior as also an
application related specification of desirable performance and Test
durability levels. The property requirement types and their clause Characterlstier defined
levels are shown in the chapters below. number
Safe operation
1.0 Introduction 4.1 Gas emission
4.2 High c u m 1 tolerance
4.3 Short circuit current and DC internal resistance
Lead acid batteries of the VRLA (valve regulated) type are 4.4 -
Protection aeainst internal imitions
~
from external mark
tbe choice power back-up storage battery for SOUICeS
telecommunication and data networks and are produced in 4.5 Protection against ground short propensity
many countries of the world. 4.6 Presence and durability ofrequired markings
4.7 Material identification
At the IEC T a l General Meeting in Kyoto, Japan in April
2000, the working group 3 (TCZI WG3) has received the
mission to reformulate and update the ancient IEC 896-2 I Performance
Standard for Stationary Lead Acid Batteries - Valve 4. II I Discharge capacity
Regulated Types and separate it into two sections. Section 4.12 I Charge retention during st0ra.q
one was to be called IEC 60896-21 and should specify the 4.13 I Float service with daily discharges
4.14 1 Recharge behavior
Methods of Test and section two, IEC 60896-22, should I
specify the Requirements.

We have reported regularly on the progress of this

standardization work at INTELEC 2000,2001,2002 and will
present the final update of this effort below. 4 20
Both parts of the standard have now reached the IEC Final 4.21
Draft of Intemational Standard (FDIS) stage and the final
Standard publication date is expected very early in 2004.
I Dimensional stability at clcvatcd ~niemalpresrurc and
Stability against mechanical abuse of units during
installation

2.0 The Standard IEC 60896-21 (in IEC FDlS stage) 3.0 The Standard IEC 60896-22 (in IEC FDlS stage)

In the part 21 of IEC 60896, the methods of test for the
quantification of properties and characteristics of all types of
all types of Valve Regulated Stationary Lead Acid Batteries
for float charge application in a static location and
incorporated into stationary equipment or installed in battery
rooms for uses in telecom, unintermptible power supply
(UPS), utility switching, emergency power or similar
3.1 The Communication between Battery Specifer/User
and Baitery Producer
The working group has identified in his discussions the
need to facilitate a more unambiguous communication of
battery requirements and battery performance data between
battery user and battery manufachuers.

IEICEAEEE INTELEC'OJ, Oct. 19-23,2003

437
 As this section of the IEC 60896 standard is the key two-
way communication channel between the battery user and
battery manufacturer, appropriate templates or forms were
included to convey the battery safe operation, performance
and durability requirements identified by the battery
specifierhser to the battery manufacturer as also for the reply,
by the battery manufacturer, of the actual representative
battery test data to the battery specifierluser.
3.2 Application related requirement selection
In order to guide the battery specifier and user in selecting
the appropriate battery requirements, he is asked to define his
application field (Telecom, UPS, 11OV DC Utility Power,
Emergency Lighting etc. etc.) and parameters such as the
operational voltage ranges, the expected minimum and
maximum operating temperatures as also the duration and
frequency of power outages, diagnostic discharges and cost
saving power consumptions discharges and ancillary factors.
Based on these basic parameters, the battery specifierher
is then encouraged to define, in the template “Appendix A”
shown below, reasonable and to the point performance
requirements for his VRLA battery, by walking step by step
through the Safe Operation, Performance and Durability
requirement sections and selecting the related performance
data ranges suggestedlavailable.
The resulting performance value mix defined in this way,
reflect thus his “real” needs of desirable VRLA battery
service life, performance robustness and safe operation.
When this requirement mix is then presented to a battery
manufacturer, the chances are higher that the quoted VRLA
battery will be in tune with his operation philosophy then a
generically specified VRLA battery.
3.3 The Requirement Statement or the Appendix A of IEC
60896-22
This template is an integral part of the standard and is
defined as “Stationary Lead Acid Batteries of the Valve
regulated Type IEC 60896-22 User Statement of
Requirements (Appendix A) ” and shown below
It is hoped that in not to distant future, it should be possible
for a non-specialist in the procurement operation of a battery
user to fill in this straightforward template and include it in.a
tender document.
438
4.0 The Requirements for Stationary VRLA Batteries in
IEC 60896-22
The requirements were defined in intense discussions, on
working group level, between battery producers, battery
specifiers and battery users and reflect quite correctly the
desire of the battery users to be able to purchase a range of
VRLA cells and monoblocs each uniquely suited to their
differing needs.
As the requirements vary kom user to user as also within a
user itself no “do-it-all-and-always-and-jorever-and-costs-
near& nothing” VRLA battery can or will realistically exist.
This reality has lead the working group to specify for
certain requirements not a single value hut a range of
requirements values going from low to high without in this
way expressing any value judgment for a particular VRLA
design or wanting to initiate a quality classification race.
The specific requirements represent mostly the status of the
art in VRLA battery performances but include in some cases,
on the express wish of battery users, also some more
challenging requirements destined to make this energy storage
system fit for more demanding applications and environments
(application pull).
These requirements cadwill be updated and adapted in the
future maintenance revisions of IEC 60896-22. These updates
occur typically every 4-6 years following IEC policy
decisions or as product performance and applications
requirements evolve.
The standard used to verify these requirements, i.e. IEC
60896-21 will, on the contrary, stay method-wise constant for
longer periods so to permit a reproducible performance test
environment except if methodological improvements make
minor changes worthwhile or necessary.
4.1 The Safe Operation Requirement for Gas Emission
No absolute gas emission level is stipulated but a statement
of gas emission, in ml gas per cell, h and Ah at 20°C or 2 5 T
under float and overcharge voltage conditions is requested.
4.2 The Safe Operation Requirement for High Current
Tolerance
The requirement stipulates that no incipient melting of
component or loss of electrical continuity within the battery
shall occur within 30s of high rate current flow. This current
is set at 3 times the Sminute rate current to 1.8OVpc.
 TABLE 2

Application summary
Load fin A or Watt) and autonomv time orotilefs) I
Minimum and maximum system float voltage
Maximum or boost charge system, voltage available
KM If yes what value?
Minimum system discharge voltagellow voltage disconnect
KIN If yes what value?
Expected minimum and maximum operating temperatures and
their duration per year
Any other relcvant information OT operational requirements

4.3 Short circuit current and DC internal resistance Data requested

4.4 Internal ignition from external spark sources Pass

4.5 Protection against ground short propensity Pass

4.6 Presence and durability of required markings Pass

4.1 Material identification Pass
4.8 Valve operation Pass
4.9 Flammabilitv m i n e of materials Data requested

4.13 Float service with daily discharges Value to b e requested as function of scrwcc envmnment

4 14 Recharge behaviour Pass

Predwt Durability in Service Compliance Inhrm&on
mandatory or on an as-needed bash
4.15 Service life at an operating temperature of 40' C Value to be requested as function of service environment

4.16 Impact of a stress temperature of 55" C o r 60" C Value to be requested as function of service environment
4 . 1 1 Abusivc over-dischargc Value t o be requested if service environment warrants
4.1 8 Thcrmal runaway sensitivity Data requested
4.19 Low temperature sensitivity Value t o be requested if service environment warrants

4.20 Dimensional stability at elevated internal pressure and Data Requested

temperature
4.21 Stability against mechanical abuse of units during Pass
installation

439
4.3 The Safe Operation Requirement f o r Short Circuit
Current and DC Internal Resistance Information
The requirement stipulates the delivery, for each of the
cells and monoblocs, of the relevant current data in Amperes
and internal resistance values in Ohm.
4.4 The Safe Operation Requirement f o r Protection
against Internal IgnitionfromExternal Sources
The requirement stipulates that when the valveharrier
assembly, utilized in the particular design, is exposed, under
defined hydrogen gas flow conditions, to external sparks no
explosion shall occur within the cell volume itself.
4.5 The Safe Operation Requirement for Protection
against Ground Short Propensity
The requirement stipulates that, when for several weeks'
500V DC electrical stresses are imposed to case-to-cover
joints and with the cells and monoblocs placed in horizontal
position, no ground shorts and associated burning phenomena
shall occur.
4.6 The Safe Operation Requirement f o r Content and
Durabiliry oflnformation and Warning Labels
The requirement stipulates that fifteen information,
needed for proper cell or monobloc identification and safe
operation, shall be present and their writing withstand
exposure to sulfuric acid, acid neutralizing agents and
aliphatic solvents.
4.7 The Safe Operation Requirement for Material
Identification
The requirement stipulates that the case and cover
material of the cell or monobloc shall be correctly identified
with the I S 0 symbol so to enhance environmentally correct
material management and disposal.
4.8 The Safe Operation Requirement of Correct Pressure
Relief Valve Operation
The requirement stipulates that the proper opening of the
vent valve shall be certified to happen before and after the
high temperature stress test.
4.9 The Safe Operation Requirement of Proper Definition
of the Flammability Rating of Materials
The requirement stipulates that, whatever flammability
rating the case and cover material offers, this value shall be
disclosed and correlated with the International Standard IEC
60707 and IEC 60965-1 1-10.
440
4.10 The Safe Operation Requirement for Pe$ormance
Information of the Intercell Connector
The requirement stipulates that the maximum temperature
of the intercell connector, reached when the cell or monobloc
is discharged at the 15 minute rate, shall reported in "C.
4.11 The Pe$ormance Requirementfor Capaciry Fulfillmenl
at the Moment of Unit Dispatch.
The requirement stipulates that each unit of a sample of
5x6 cells or monoblocs shall show, at the moment of dispatch
and tested at the IOh, Xh, 3h, Ih and 0.25h rate, at least 95%
of the respective rated capacity.
4.12 The Performance Requirement for Capaciry Retention
during Storage.
The requirement stipulates that, after storage at 25°C for
180 days, all units shall have at least 70% of the rated 3 hour
capacity remaining.
4.13 The Perfrmance Requirement f o r Float Service Lge
with Daily Discharges
The requirement stipulates that the following alternative
and application environment related cycle life ranges shall be
achievedrequired
For reliable mains power 250 cycles
For unreliable mains power ?I50 cycles
For very unreliable mains power 2300 cycles
It shall be noted that this cycle service relies exclusively
on recharges under float voltage conditions. The daily
discharge, with a current of 2x Ilo, withdraws 40% of the 10h
rated capacity.
4.14 The Peformance Requirementf o r Recharge Behavior
The requirement stipulates that after a 10h rate discharge
to 1.8OVpc and recharge, all the units shall show an available
capacity, when discharged again after 24h and 168h of
recharge duration, of >90% of C, (10h rate) and 298% C,
(10h rate) respectively.
4.15 The Durabiliry Requirement f o r Service Li/e at an
Operating Temperature of 40°C
The requirement stipulates that the following altemative
and exposure duration related service life ranges should be
achievedrequired
For brief duration exposure time 2500 days
For medium duration exposure time ?750 days
 For long duration exposure time 21100 days
For very long duration exposure time 21700 days
It shall be noted that the residual capacity is determined at
the 3h rate, after float in a drj atmosphere and without float
voltage compensation, and with the end-of-life criterion set at
0.8C, (3h rate).
4.16 The Durability Requirement for Infarmation on the
Impact o f a Stress Temperature of55'C or 6 0 T
The requirement stipulates that the following altemative
and exposure duration related 5 5 T service life ranges,
monitored with 3h rate diagnostic discharges, should be
achievedrequired
For brief duration exposure time 2150 days
For medium duration exposure time t250 days
For long duration exposure time ?350 days
For very long duration exposure time 2500 days
When the diagnostic discharges are made at the 0.25h
rate, the following altemative and exposure duration related
55°C service life ranges should be achievedhequired
For brief duration exposure time 275 days
For medium duration exposure time 2125 days
For long duration exposure time ?175 days
For very long duration exposure time 2250 days
When the stress test is alternatively carried out at 60"C,
then the relative durations achievedrequired, are 70 to 73%
ofthe durations achieved at 55°C.
4.17 The Durability Requirement /or Information on the
Impact ofAbusive Over-Discharges
The requirement stipulates that the following, application
environment related capacity recovery performances shall be
achievedrequired
With good battery replacement infrastructure n.a.
With poor battery replacement infrastructure 20.85
With reliable mains supply and voltage control n.a.
With poor mains supply and voltage control 20.90
n.a. - Requirement not applicablehot relevant for such an
operating condition
The recoveredavailable capacity is determined with a 3h
rate discharge and expressed as &action of the 3h. rated
capacity.
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4.18 The Durability Requirement for information on the
Thermal Runaway Sensitivity
The requirement stipulates that, in a defined layout, the
unit string shall have enough thermal stability so not reach
POT after 168h at 2.45Vpc or after 24h at 2.6OVpc.
In both cases unlimited current shall be available for
behavior verification and the temperature/current evolution
over time to 60°C or for 168h shall also be obtainable from
the battery manufacturer.
4.19 The Durability Requirement Jar the Impact of Low
Temperature Service on Capacity
The requirement stipulates that the following alternative,
and application environment related fieezing insensitivity
should be achievedrequired
When battery will not experience freezing n.a.
When battery may experience fieezing Z0.95
n.a. - Requirement not applicablehot relevant for such an
operating condition
Next to a residual capacity of Z0.95 C,, (3h) no
mechanical damage such as container splitting or bulging
shall occur.
4.20 The Durability Requirement /or the Dimensional
Stability at Elevated intemal Pressures and
temperatures
The requirement stipulates that the dimensional change of
the cell or monobloc, after 24h float at 50°C and at maximum
internal operating pressure, shall be made available to the
battery specifierher and expressed in mm and in percent
change
4.21 The Durability Requirement of Stability Againsf
Mechanical Abuse
The requirement stipulates that the cells and monohlocs
shall survive two consecutive drops onto concrete floor fiom
specified heights. These drop heights are related to the unit
weight (100"/5OKg to 25"/>100Kg) and the impact shall
be twice on the same short edges and comer.
 TABLE 3
Appendix B of IEC 60896-22
Statlonary Lead Add Bstteries of the Valve Regulated Type
IEC 60896-22 Supplier Statement of Product Range Test Resulta (Appendix E)
1
1. Supplier informntion
I Product manufacturer I I
Manufacturing site of tested product
Product name
Product model range
Product comorisine the model ranee I
1 Product tested I I
Product Safe Operstlon in Service IEC 6089621 Test Clause Resnlt

4 I Gas emission (at the float voltage and at 2 40Vpc)

4.2 High current tolerance
4 3 Short c ~ c u t and
t DC intemal resistance Amperes Ohm
4.4 Internal lanltion from external sDark Sources
4.5 Protection against ground short propensity
4.6 Presence and durability of required markings
4.7 Material identification Case cover
4.8 Valve operation Beforc After
4.9 Flammability rating of materials Case Cover
4.IO Intercell connector performance "C
, .
Product Performance in Service
4.1 I Discharge capacity ClO CS C, C CO.25
4.12 Charee retention durine storsee
4.13 Float service with daily discharges Cycles Car Cab

Product Dnrabillty In Servlce

4 15 Float S ~ ~ V L Clife
C at 40-C Days
4 16 Impact of stress temperature of 55°C or 6 0 T Days at C, rate at 55°C or 6 0 T
I I D a n at Cn ?r rate at 55°C or 60°C I
14.17 Abusive over-discharae I I I
4.18 Thermal runaway sensitivity
14.19 Low temoerature sensitivitv I I I

I 4.20 Dimensional stability at elevated internal pressure and

temDerature I mm %
I
mechanical abuse of units during
I
Company Name, Officer Name, Company address, date, place, signature
1

442
5.0 The Product Range Test Result Information for
Stationary VRLA Batteries in IEC 60896-22

The IEC Standard 60896-22 Requirements contains a

template for the standardized information of the battery
specifierher about the results obtained with VFUA cells
and monoblocs of a particular type range when tested
according to IEC 60896-21 Test Methods.

This is the Appendix B of IEC 60896-22 and is shown

in table 3 above. Its layout mirrors the Appendix A so that
any comparison between the requirements (in A) and the
actual performance (in B) is straightfonvard and easy.

This document is a dated, official and certified

document containing binding product information backed
by the signature a qualified company officer.

Next to this summary document the battery

manufacturer maintains test result documentation
complying with the clauses 3.1 to 3.5 of IEC 60896-21 and
which shall be made accessible to battery specifiers and
users.

5.1 Compliancy of an Stationary LeadAcid Battery of the

VRLA type to IEC 60896-21 or IEC 60896-22

Future users of these standards are reminded that an

Stationary Lead Acid Battery of the Valve Regulated Type
(VRLA) does not per se comply to these standards but the
test methods used and the data presentation defining their
behavior do. For this reasons no labeling “Battery
conforming/complying to IEC 60896-21 or 60896-22”
should ever appear.

6.0 Conclusion

The IEC TC21 working group 3, with members from

Asia, Australia, Europe and the Americas, has in little more
than 1000 days fully restructured, reformulated and
reevaluated the IEC Standard for Stationary Lead Acid
Batteries of the Valve Regulated Type (VRLA) and is
confident that the present document content and structure
will be of great help to battery users and manufacturers
alike in developing, defining and obtaining stationary
batteries suited for the needs of the industry.

7.0 Acknowledgements

The authors wish to thank all involved battery experts and

their companies for their multiple contributions in the
elaboration of these Standards.

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