VRLA Battery Operation Manual (AGM) : Huawei Technologies Co., LTD

VRLA AGM BATTERY OPERATION MANUAL˄AGM˅ PUBLIC
VRLA Battery Operation Manual

(AGM)
Prepared by: Zhou Jianhong/00136483 Date: 2008-11-3
Reviewed by: An Qiangxin/00112667 Date: 2008-12-1

Reviewed by: Date:
Granted by: Date:
Huawei Technologies Co., Ltd.
All rights reserved
2008-11-3 Public Page 1 of 23

Revised Record
Date Revised edition Describe Author

2008-11-3 V1.0 First draft Zhou Jianhong/00136483

Catalogue
Foreword .....................................................................................................................................6
Chapter 1 Summary................................................................................................................7
1.1 Application Scope..................................................................................................................... 7
1.2 Product features ....................................................................................................................... 7
1.3 Product structure ..................................................................................................................... 8
1.4 Types.......................................................................................................................................... 8
1.5 Fundamentals of operation...................................................................................................... 9
Chapter 2 Technical Characteristics ...................................................................................10
2.1 Charging characteristic ......................................................................................................... 10

2.1.1 Charging formula ................................................................................................................................ 10
2.1.2 Charge curve ....................................................................................................................................... 11
2.2 Discharging characteristic ..................................................................................................... 11
2.3 Capacity calculation............................................................................................................... 13

2.3.1 Capacity calculation formula............................................................................................................... 13
2.3.2 Example .............................................................................................................................................. 13
Chapter 3 Battery Installation .............................................................................................14
3.1 Installation environment........................................................................................................ 14
3.2 Checking before installation.................................................................................................. 14
3.3 Installation cautions ............................................................................................................... 14
3.4 Installation tools ..................................................................................................................... 15
3.5 Installation procedure............................................................................................................ 16

3.5.1 Indoor battery rack installing procedure.............................................................................................. 16
3.5.2 Outdoor battery cabinet installing procedure ...................................................................................... 18
3.5.3 Check after installtion ......................................................................................................................... 20
Chapter 4 Battery Maintenance ..........................................................................................22

4.1 Maintenance cautions .............................................................................................................22
4.2 Maintenance for battery.........................................................................................................22

4.2.1 Monthly maintenance.......................................................................................................................... 22
4.2.2 Quarterly maintenance ........................................................................................................................ 23
4.2.3 Yearly maintenance ............................................................................................................................ 23
4.2.4 Three yearly maintenance ................................................................................................................... 23

Diagram Catalogue
Figure 1 Product Architecture of AGM Battery ............................................................................................... 8

Figure 2 Curves of Charge Feature .................................................................................................................. 11
Figure 3 Curves of Discharge Feature.............................................................................................................. 12
Figure 4 Curves of Discharge Capacity and Ambient Temperature ............................................................. 12
Figure 5 The Tools Prepared before Installation ............................................................................................ 16
Figure 6 Guide for Rack Installation of AGM Battery................................................................................... 18
Figure 7 Guide for Cabinet Installation of AGM Battery .............................................................................. 20
Table 1 Battery Types and Dimensions.............................................................................................................. 8

Table 2 Equalizing Charge Duration Parameter ............................................................................................ 10
Table 3 Capacity Coefficient at Different Backup Time................................................................................. 13
Table 4 Torque for Different Bolts ................................................................................................................... 15
Table 5 The Main Items Needed to be Checked after Installation................................................................. 20

Foreword
This manual introduces the technical parameters, specification, capacity calculation,
installation and maintenance of AGM battery. It mainly contains four chapters:
Chapter 1: Product application, technical parameters, specification and working principle.
Chapter 2: Technical characteristic of AGM battery.
Chapter 3: Installation of AGM battery.
Chapter 4: Maintenance of AGM battery.
Abbreviation:
Abbreviation English Name
VRLA Valve Regulated Lead Acid
AGM Absorbed Glass Mat

Chapter 1 Summary
1.1 Application Scope
Ŷ Communication switching and transmission system

ŶMobile communication system
Ŷ Microwave relay station
Ŷ Solar energy system
ŶPower plant and power transformer system
ŶNavigation aid signaling system
ŶRadio and broadcasting station
ŶNuclear power plants
ŶOther backups
1.2 Product features
l Safety: The valve can automatically regulate the internal pressure of the battery, and
the one way valve can prevent the outer air into the battery. The special filter prevents
the acid leakage and the explosion probability.
l Easy installation: The battery can be installed vertically or horizontally. Only normal
ventilation is required.
l High nominal voltage: The nominal voltage is the highest except lithium cell, fewer
cells are needed to achieve the required total voltage.
l Low cost.
l Wide capacity range: Up to several thousand Ah.
l Low resistance: About several milliohm, can adapt to discharge with heavy current.
l Easy maintenance: No topping-up water and acid.
l Excellent sealing proof: No leakage, no acid mist, no equipment corruption.
l Low self-discharge rate: Self-discharge rate less than 2% per month at 25ć.

l Wide temperature range: -20ć̚ˇ50ć.
1.3 Product structure
Figure 1 Product structure of AGM Battery
1.4 Types
Table 1 Battery Types and Dimensions
Rated Rated Max Dimensions (mm)

Weight
Type Voltage Capacity Overall
Length Width Height (Kg)
(V) (Ah) Height
2V 200Ah 2 200 111 184.5 362 372 15.3
2V 300Ah 2 300 151 184.5 362 372 22.2
2V 400Ah 2 400 176 197 362 372 28.0
2V 500Ah 2 500 205 241 362 372 36.5
2V 650Ah 2 650 307 184 359 371 46.6
2V 800Ah 2 800 410 184 555 566 57.0
2V 1000Ah 2 1000 471 186 555 566 72.75

2V 2000Ah 2 2000 492 358 371 398 140.0
2V 3000Ah 2 3000 762 358 371 398 210.0
1.5 Fundamentals of operation
The electrochemical reaction of the lead acid battery involves lead, lead dioxide and an
aqueous solution of sulfuric acid.
The following formula shows the main chemical reactions for discharge and charge:
Disch arg e
PbO 2 + 2H 2SO 4 + Pb ® 2PbSO 4 + 2H 2O
Charge
2PbSO 4 + 2H 2O ® PbO 2 + 2H 2SO 4 + Pb
The side reaction takes place at the end of charge:
2H2O ® 2H 2 - + O 2 -
This side reaction leads to water loss gradually, therefore, pure water have to be added
regularly to keep the battery work normally.
AGM battery adopts the design of barren-liquor, and there are a mass of paths in the separator
which is made up of micro porous glass fiber. Also special alloy grid is chosen to increase the
overpotential of hydrogen evolution on the negative plate, which prevents generation of
hydrogen. Therefore, the oxygen generated from positive pole diffuses through separator to the
negative pole, then reacts quickly there and recombined into water. The reactions are as
follows:
O 2 + 2Pb ® 2PbO ; PbO + H 2SO 4 ® PbSO 4 + H 2O
The float current passing through cell then reduces, instead of evolving hydrogen, on the
negative electrode, the formed lead sulfate back to lead and sulfuric acid so that a closed cycle
(oxygen recombination cycle) is obtained.
So it is possible to build battery in sealed structure.

Chapter 2 Technical Characteristics
2.1 Charging characteristic
2.1.1 Charging formula
Ł Floating charge
The floating charge voltage of the battery is set as 2.23V/cell (at 25ć), the initial charge
current is not more than 0.15C10A. When the ambient temperature deviates from 25ć, the
floating charge voltage should be adjusted. The coefficient of temperature adjustment is
-0.003V/cell·ć. The adjustment is denoted as the following formula:
U f = 2.230 - (t - 25 ) ´ 0.003
Uf —Floating charge voltage after setting-up; t —Ambient temperature
ł Equalizing charge
The equalizing charge voltage is usually set as 2.35V/cell (25ć), and the maximum
charging current is 0.15C10A. The equalizing charge duration is set as follows.
Table 2 Equalizing Charge Duration Parameter
Equalizing charge Conditions to exit the

Equalizing charge condition
duration equalizing charge
Before operation, or after installation, or 1~10h, The
1
commissioning actual time should When the equalizing charge
The floating charge current 0.05C10A, according to the current is lower than
2 and the duration of continuous charging conditions to exit 0.5%C10A and the duration is
30 min the equalizing longer than 2h.
3 After battery capacity checking charge
When the float voltage lower than

4
2.18V/cell When the equalizing charge
12h
Equalizing charge should be periodic time is up to 12h
5
done once every six months commonly.
2.1.2 Charge curve
The batteries should be recharged at a voltage of 2.23V/cell at 25ć after discharge
immediately. The limited current is 0.15C10A (battery used outdoor) and 0.10C10A (battery
used indoor). The charge time depends on the discharged capacity and the initial charge
current. Figure 2 shows that the charge performance of the AGM battery with a depth of
50%C10 and 100%C10, at a limited charge current of 0.1C10A and constant voltage of
2.23v/cell at 25ć.
Figure 2 Curves of Charge Feature
2.2 Discharging characteristic
Conventionally, the rated capacity of a battery in the communication industry is defined as the
ten-hour-rate discharge capacity (I=0.1C10A) at 25ć, i.e., a fully charged battery is discharged
at 25ć with 0.1CA current until the operation voltage declines to 1.80V/cell, The unit of
capacity is Ah, ampere hour.
For the same battery at the same condition, there is an inverse ratio between discharged
capacity and discharge current. Less the discharged capacity, heavier the discharge current
increases.
The discharge curves of different current are shown in Figure 3:
Figure 3 Discharge Curves
In addition, the effect of ambient temperature on discharge capacity is shown in Figure. 4:
Figure 4 The Effect of Temperature on the Discharge Capacity

2.3 Capacity calculation
2.3.1 Capacity calculation formula
W ´ t ´ 1.04 ´ 1.25
C=
Vr ´ h
In which˖C --- Capacity (Ah) W --- Load power (W)

t--- Backup time˄h˅ 1.04--- Voltage coefficient
1.25 --- Aging coefficient Vr --- Rated voltage˄48V˅
Ș--- Capacity coefficient (%)
Capacity coefficient is relevant to the backup-time as the follows:
Table 3 Capacity Coefficient at Different Backup Time
t (h) 0.5 1 1.5 2 3 4 5 6 7 8 9 10 12 16
Ș 0.4 0.55 0.63 0.7 0.75 0.8 0.85 0.9 0.92 0.95 0.98 1 1.01 1.03
2.3.2 Example
E.g.: The load power of 48V system is 3000W; standby time is 6 h, Please figure out the
battery capacity.
Solution : W˙3000ˈVr ˙48ˈt˙6ˈ n˙2ˈ IURPWKHWDEOHNQRZȘ˙0.9
Thus, battery capacity calculate˖
W ´ t ´ 1.04 ´ 1.25 3000 ´ 6 ´ 1.04 ´ 1.25

C= = 澵542澠Ah澡
Vr ´ h 48 ´ 0.9
Battery capacity select˖The battery capacity select is 300Ah with two strings parallel
connection or 600Ah with one string.

Chapter 3 Battery Installation
3.1 Installation environment
1. The ambient temperature of battery installation is suggested at 25ć.
2. The installation environment should be dry, clean and ventilating, free of organic solvent
and corrosive gas etc.
3. Direct sunlight should be avoided, and keep away from heater or electric power switch
more than two meters.
4. The foundation of installation should meet the weight bearing requirement of the battery
block.
3.2 Checking before installation
1. Please check the outer package before unpacking. Once there are breakages on the
package, check the appearance of each battery to make sure that everyone is in fine
condition.
2. Check the number of batteries and accessories according to the packing list and read the
installation manual and battery installation drawing carefully.
3. Check the open circuit voltage (OCV) of each battery before installation: OCV should be
not less than 2.15V (2V). Otherwise, battery recharging is needed.
3.3 Installation cautions
1. Check the ambient temperature to make sure it meets the requirement mentioned above.
2. Please program the position of battery string first according to the practical installing
status.
3. To avoid any impact during installation.
4. The space between two batteries in the same string should be more than 15 mm.

5. Please read the attached installation drawing before installing and DO NOT modified it
without being authorized.
6. Less than four strings parallel connection is appreciated.
7. DO NOT open the regulating valve and put anything else into the battery.
8. Do not connect batteries from different supplier.
9. Short circuit is strictly forbidden.
10. Please clean the surface of the connection cable, copper bar and battery terminal before
connection
11. All the tools must be insulated.
12. Terminal screw connections must be tightened, the torque of different screws are shown
in table.4
13. Check-up the total voltage of the battery string before operation.
Table 4 Torque for Different Bolts

Bolts Torque˄NgM˅
M6 8
M8 11-15
M10 22
3.4 Installation tools

Figure 5 The Tools Prepared before Installation
3.5 Installation procedure
3.5.1 Indoor battery rack installing procedure
1. Please read the attached connection drawing before installing the batteries into the racks.
2. Select the installation site and mark the line.
3. Drill and install the expansion bolts.
4. Install side rack.
5. Install support accessories.
6. Fix side rack and support accessories.
7. Install the batteries, install the 2V batteries of each side at the bottom, and then the four in
the middle.
8. Install the rest of batteries.
9. Install the resistant bar, and fixed them with M8 bolts.
10. Install the output terminal, fixed the output terminal with M8 hexagon-headed bolts.
11. In the end, install the connector and insulation cover, install the connector according to

figure of assemble and then fix the insulation cover.

Figure 6 Guide for Rack Installation of AGM Battery
3.5.2 Outdoor battery cabinet installing procedure
1. Please read the attached connection drawing before installing the batteries into the cabinet.
2. Connect the cabinet to the ground at the installation site with the ground bolts.
3. Drill and install the expansion bolt.
4. Move the cabinet to the point and tighten expansion bolts up(with the front gate’s
accessories removed).
5. The connection position of positive and negative pole should be preplanned before battery
installation, as well as the battery rank order and the orientation of positive and negative
polarity.
6. Remove the front blocked sides, and then install batteries from the bottom to upper (with
the front gate’s accessories removed).
7. Install the connection wires of the battery.
8. Install the front blocked sides, connect connecting barsǃsoft cable and terminal safety
cover(with the front gate’s accessories removed).
9. In the end, install the front gate’s accessories.


Figure 7 Guide for Cabinet Installation of AGM Battery
3.5.3 Check after installtion
After installation, check carefully and keep record.
Table5 The Main Items Needed to be Checked after Installation

NO. Items Results
The polarities are in right connection, the voltage of the

1 battery group between positive and negative output ƑY ƑN
terminals are higher than 48V
The voltage of each cell in the same battery group is

2 ƑY ƑN
between 2.1 and 2.2V
If several battery groups are parallel connection, each
3 output positive terminals should be connected together and ƑY ƑN
negative terminals together
The positive and negative output terminals of the battery
4 group should be connected with the counterparts of the ƑY ƑN
charge device
5 All of the bolts, nuts and screws are fastened tightly ƑY ƑN
No unnecessary connecting wires or tools etc. are left on
7 ƑY ƑN
the batteries or racks
8 The appearances of the batteries have no cracks or damages ƑY ƑN

The safety valve has been twisted tightly and has no

9 ƑY ƑN
looseness or damage
10 The ambient site of the batteries and rack is clean ƑY ƑN

All of the parameters of the battery group, such as the
11 equalization charge and float charge currents, have been set ƑY ƑN
correctly
The resistances between output terminals and the rack are
12 ƑY ƑN
normal
13 Other items need to be checked ƑY ƑN

Chapter 4 Battery Maintenance
4.1 Maintenance cautions
1. All the tools must be insulated. Never place the metal tools on the bareness terminal of a
battery.
2. DO NOT use any organic solvent clean battery.
3. DO NOT open the safety valve or put anything else into the battery.
4. NO smoking or ignition in the battery room.
5. Recharge immediately after discharge.
6. Professional maintenance staff are appreciated.
4.2 Maintenance for battery
Periodic inspections and maintenance are very necessary. Good habit to record the details of
battery maintenance is helpful to deal with any problem about battery operation.
4.2.1 Monthly maintenance
n Physical conditions about the battery, such as leakage, distention, distortion, break or
damage.
n Charge voltage and current settings.
n Battery voltage and voltage deviation of several cells / blocs.
n The discharge conditions.
n Surface temperature of several cells / blocs and battery room temperature.
n The storage conditions.
n The cleanliness of the battery and equipment.
n Terminal screw connections for tightness.

n And other conditions relevant to safety issues and battery’s service life (battery room
ventilation, for example).
4.2.2 Quarterly maintenance
n Repeat monthly inspection.
n Measure and record the floating voltage of each battery.
n If more than two cells’ voltages are less than 2.18V after temperature adjustment, the
battery group needs to be equalizing charged.
4.2.3 Yearly maintenance
n Repeat quarterly maintenance and inspection.
n Check whether the terminal screws are loose or not.
n Make a discharge test to check with exact load every year, discharging 30%-40% of rated
capacity.
4.2.4 Three yearly maintenance
n Make a capacity test every three years and annually after six years’ operation.
n If the capacity of the battery decreases to lower than 80% of rated capacity, the battery
should be replaced.

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VRLA AGM BATTERY OPERATION MANUAL˄AGM˅ PUBLIC

VRLA Battery Operation Manual

Prepared by: Zhou Jianhong/00136483 Date: 2008-11-3

Reviewed by: An Qiangxin/00112667 Date: 2008-12-1

Huawei Technologies Co., Ltd.

All rights reserved

2008-11-3 Public Page 1 of 23

Date Revised edition Describe Author

2008-11-3 Public Page 2 of 23

1.1 Application Scope..................................................................................................................... 7

1.2 Product features ....................................................................................................................... 7

1.3 Product structure ..................................................................................................................... 8

1.5 Fundamentals of operation...................................................................................................... 9

Chapter 2 Technical Characteristics ...................................................................................10

2.1 Charging characteristic ......................................................................................................... 10

2.2 Discharging characteristic ..................................................................................................... 11

2.3 Capacity calculation............................................................................................................... 13

Chapter 3 Battery Installation .............................................................................................14

3.1 Installation environment........................................................................................................ 14

3.2 Checking before installation.................................................................................................. 14

3.3 Installation cautions ............................................................................................................... 14

3.4 Installation tools ..................................................................................................................... 15

3.5 Installation procedure............................................................................................................ 16

Chapter 4 Battery Maintenance ..........................................................................................22

2008-11-3 Public Page 3 of 23

4.1 Maintenance cautions .............................................................................................................22

4.2 Maintenance for battery.........................................................................................................22

2008-11-3 Public Page 4 of 23

Figure 1 Product Architecture of AGM Battery ............................................................................................... 8

Table 1 Battery Types and Dimensions.............................................................................................................. 8

2008-11-3 Public Page 5 of 23

Abbreviation English Name

VRLA Valve Regulated Lead Acid

AGM Absorbed Glass Mat

2008-11-3 Public Page 6 of 23

1.1 Application Scope

Ŷ Communication switching and transmission system

ŶPower plant and power transformer system

ŶNavigation aid signaling system

ŶRadio and broadcasting station

ŶNuclear power plants

1.2 Product features

the acid leakage and the explosion probability.

cells are needed to achieve the required total voltage.

l Wide capacity range: Up to several thousand Ah.

l Easy maintenance: No topping-up water and acid.

l Excellent sealing proof: No leakage, no acid mist, no equipment corruption.

2008-11-3 Public Page 7 of 23

l Wide temperature range: -20ć̚ˇ50ć.

1.3 Product structure

Figure 1 Product structure of AGM Battery

Table 1 Battery Types and Dimensions

Rated Rated Max Dimensions (mm)

2V 200Ah 2 200 111 184.5 362 372 15.3

2V 300Ah 2 300 151 184.5 362 372 22.2

2V 400Ah 2 400 176 197 362 372 28.0

2V 500Ah 2 500 205 241 362 372 36.5

2V 650Ah 2 650 307 184 359 371 46.6

2V 800Ah 2 800 410 184 555 566 57.0

2V 1000Ah 2 1000 471 186 555 566 72.75

2008-11-3 Public Page 8 of 23

2V 2000Ah 2 2000 492 358 371 398 140.0

2V 3000Ah 2 3000 762 358 371 398 210.0