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BATTERIES
4.1 General
The storage battery is the basis of most UPS supplies. It is essential that it can be relied upon to
provide the required power for a specified period and within the specified voltage limits. The
choice
of battery type is therefore very important. Many types of batteries exist, however three types in
particular are best suited for instrument power supply purposes. These are the lead-acid battery,
which
comes in two main types - vented and valve-regulated (VRLA), and the Nickel-Cadmium type. In
this
handout these are referred to in short as Pb (v), VRLA and NiCd batteries respectively. The choice
between these three types is largely dependent upon the application involved, and it is therefore
necessary to discuss the characteristics of each in some detail. Initially, however, it is worth
discussing the basic aspects of battery capacity, which applies to all three types of batteries, in
order
to facilitate the detailed discussion on each type.
4.2 Battery Capacity
For most purposes a battery is a series connection of a group of cells, the precise number of which
depends on the particular voltage requirements. The capacity of the battery is determined by the
capacity of the individual series-connected cells.
The capacity of a storage battery is normally expressed in Ampere-Hours (Ah). It is a direct
measure
of the electricity that the battery is able to deliver, i.e. it is the product of the current in amperes
and
the period for which the current can be supplied. However, when specifying a battery capacity it is
necessary to take several factors into consideration:
- The rate at which a battery is discharged can affect its capacity, the higher the discharge rate, the
lower the capacity, e.g. if a Pb(v) battery is quoted as having a capacity of 100 Ah at the 10-hour
discharge rate. This means that it can be discharged at a constant 10 A rate for 10 hours while
maintaining the load voltage above a certain value. If, however, the same battery is discharged
within a period of 1 hour it will only have a capacity of about 50 Ah i.e. a constant current of 50 A
for 1 hour.
- The voltage output of a battery on load reduces as it is discharged. In most applications certain
permissible voltage limits are applied to a system and, to avoid falling below the lower limit, the
capacity of the battery must be specified such that it can deliver sufficient current while
maintaining the voltage limits. It is therefore necessary to consider the 'end voltage' when
specifying a battery capacity, particularly because the required value as dictated by the load
requirements may not be the same as the end voltage used by the manufacturer when quoting the
capacity of a cell.
- The capacity of a cell also varies with the temperature of the battery, such that when specifying a
battery capacity it is essential to quote the minimum temperature at which the battery will be
expected to supply the required capacity, e.g. a Pb(v) battery with 100 Ah capacity at 15°C might
have a capacity of about 95 Ah at 10°C.
The required capacity of a battery can be calculated by determining the load, which the battery
will be
expected to supply, the period for which the supply is required, and the voltage limits of the
system.
4.3 Lead Acid (Vented) Batteries
The constituents of a lead acid storage cell are two dissimilar electrodes immersed in an
electrolyte.
The physical construction of the electrodes, or plates, differs from one manufacturer to another but
the
materials used are the same:
Positive active material - lead dioxide (PbO2)
Negative active material - spongy lead (Pb)
Electrolyte - dilute solution of sulphuric acid (H2SO4) in water
During discharge the electrolyte reacts with the plates, such that, when fully discharged, both
positive
and negative plates are coated in lead sulphates and the electrolyte is very much diluted with
water.
Pb + PbO2 + 2 H2SO4
discharge
charge 2 PbSO+H20
During charging this chemical process is reversed, with oxygen and hydrogen being evolved and
the
original compositions of the electrodes and electrolyte being regained. Consequently, the amount
of
acid in the electrolyte is a measure of the state of charge of the cell. The concentration of the
electrolyte is determined by the specific gravity of the electrolyte, hence a measure of the specific
gravity will give a direct indication of the state of charge.
The majority of Pb(v) batteries used in UPS applications are of the "Plante" positive plate type. In
this
type of cell construction the negative plate is normally a "pasted" plate in which the active
material is
applied to the plate structure in a paste form. The positive plate initially consists of pure lead, as
opposed to a paste, normally formed by numerous thin vertical laminations, strengthened by a
series
of horizontal cross-ribs. The laminations effectively increase the surface area by up to 12 times
that of
a plain lead plate of similar dimensions. Plante cells have a life expectancy of approximately 25
years.
Other cell constructions of the vented lead acid type include Tubular plate and Flat plate.
Pb(v) batteries are generally enclosed in a transparent, non-flame propagating plastic container.
Vent
plugs are installed on the battery containers to permit easy access for topping up, for ventilation,
and
to permit removal of the gases produced during charging. The plugs are normally of the labyrinth
type
and also designed to prevent acid from being splashed out of the cells during transport.
Other special types of vent plugs are available examples of which are:
- a "gas dryer plug" which retains a large amount of the acid gas escaping from the electrolyte by
means of a special granulate filling.
- a "flame arresting plug" which in case of ignition of gases escaping from the cell, inhibits the
flame from travelling inside the cell.
- a “ceramic funnel plug” which fulfils the same function as the flame retardant plug but in
addition
it allows testing and refilling with distilled water by means of a tube, without having to remove the
plug.
The main disadvantage of Pb(v) cells is their susceptibility to corrosion of the positive plates,
collector bars, or terminal pillar. Especially pillar corrosion can be a cause of concern if the pillar
seal
is not adequately designed to prevent escape of electrolyte to the pillar and causing it to corrode.
The
pillar corrosion usually takes place underneath the battery lid where the volume of the lead
sulphate,
produced by this corrosion, eventually leads to cracking of the battery container.
A further disadvantage being their susceptibility to damage, or greatly reduced lifetime, caused by
deep discharging of the battery and AC ripple. Damage will arise if the cells continue to be
discharged
below cell voltage of 1.6 V per cell. This may result in cell voltage reversal from which the cell
cannot recover.
End of battery life is signified by a loss of capacity, which is likely to occur, by structural failure
of
internal plates, connectors, the cracking of battery container due to pillar corrosion, negative plate
sulphation or the growth of dendrites due to AC ripple causing an internal cell short circuit.
4.4 Lead Acid (Valve Regulated) Batteries
VRLA cell basic chemistry is similar to the Pb(v) cell except it utilises the principle of gas
recombination. Gas recombination is defined as the process whereby, during charging, the positive
plate reaches the top-of-charge before the negative plate, producing oxygen, which then diffuses
rapidly to the negative plate where it recombines in a closed cycle to form water. The following
sequence of reactions takes place:
- H2O ----- 2H(+) + O2 + 2e
- Pb + O2 ----- PbO
- PbO + H2SO4 ----- PbSO4 + H2O
- PbSO4 + 2H(+) + 2e ----- Pb + H2SO4
In terms of cell construction, VRLA cells rely on the use of special glass micro fibre separators to
achieve efficient oxygen recombination. These materials have a large, uniform volume of fine
pores
and, with the separator only partially saturated with electrolyte, there is a connected path in the gas
phase between the plates. This design allows the oxygen to diffuse readily from the positive to the
negative plate where it is recombined. Flat pasted-plates are used for both electrodes and grid
alloys
with high hydrogen over-potential are used.
Cell containers are built with cases and lids moulded from polymers with a high elastic modulus
and
high fracture toughness so that container distortion is minimal under internal pressure. The pillar
seals
need to be highly reliable and a non-return valve is incorporated to act as a pressure relief valve.
Cell
operation takes place in a pressure range from 3-5 psi, above which the relief valve is supposed to
operate.
The main advantages of VRLA cells, on other type of cells, are that they require less maintenance
(no
topping- up), no special (forced) room ventilation, and are appreciably less expensive than the
others.
One disadvantage of VRLA cells is that they tend to get damaged more readily by deep
discharges, by
overcharge and by high ambient temperatures than traditional Pb(v) battery types. This is because
the
cell has a limited quantity of electrolyte and when this is depleted short circuits can develop in the
separator system. For that reason rapid charging for VRLA cells is not allowed and in some
applications, a low voltage disconnected facility can be installed on the battery circuit so as to
disconnect it from the load when discharged.
The principal disadvantage of VRLA cells though is its high dependence on cell temperature and
its
relatively low lifetime. VLRA cells are sensitive to variations in temperature because of the cell
compactness and the limited amount of electrolyte used in them. The most optimal operation
temperature for VRLA is 20°C + 2°C. Outside these temperature limits the battery capacity and
lifetime is reduced. Temperature dependence is also affected by the float voltage used i.e. with
high
cell temperatures a lower float voltage is required in order to compensate for the extra heat energy
to
be absorbed by the cell. High cell temperatures and high float voltages effectively reduce service
lifetime but in any case the expected lifetime of a VRLA cell does not exceed 10 years which is
less
than half that of other `traditional battery types. Reference should be made to BS 6290 Pt 4 and
VRLA cells specified as being classified as 1 H 23. This ensures longest lifetime and durability.
4.5 Nickel-Cadmium Batteries
The most common type of NiCd cells used in UPS applications is the pocket-plate type. The
active
material for the positive plate is trivalent nickel hydroxide (NiOH), and for the negative plates a
mixture of cadmium and iron (Cd+ Fe). On battery discharge the positive plate active material is
reduced to divalent nickel hydroxide and the negative plate active material to cadmium hydroxide
in
accordance with the following reaction:
2 NiOOH + 2 H2O + Cd
discharge
charge 2 Ni (OH)2 + Cd(OH)2
The electrolyte is an aqueous solution of potassium hydroxide (KOH) containing small quantities
of
lithium hydroxide (LiOH) or lithium fluoride (LiF) to improve cycle life and high temperature
operation. The electrolyte function is to provide an adequate supply of ions and water to support
the
reaction of the two plates. The active materials of NiCd cells are relatively insoluble in the
electrolyte
and the overall charge and discharge reactions result in transfer of a relatively small amount of
water