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1973 TO 2008
2
Rugged construction and reliable performance
in extreme temperatures make Cyclon
8
3
Powerful design:
Appendix A............................................................................................................................................................................. 17
100
0
-4 -30 -20 -10 0 10 20 30 40
Temperature, C
1The C10 rate of a battery is defined as the charge or discharge current in amperes that is numerically equal to the rated capacity of a cell in ampere-
hours at the 10 hr rate of discharge. Thus the 2C10 rate for a 5Ah cell would be 10 amps.
2.1
time or alteration of charge voltage may be required before
2 normal charging can resume.
1.9
1.8
Disconnecting the battery from the load will totally eliminate
1.7
the possibility of an overdischarge, provided that it is put
1.6
back on recharge immediately after the discharge. Doing so
0 1 2 3 4 5 6 7 8 9 10 11 12 will allow each cell to provide its full cycle life and charge
Time in hours at 25C (77F) capabilities.
It is important to note that when the load is removed
Figure 4-2: CYCLON Battery High Rate Voltage Profile from the battery, its terminal voltage will increase - up to
approximately 2 volts per cell. Because of this phenomenon,
2.3 some hysteresis must be designed into the battery
2.2
1C 2.2C disconnect circuit so that the load is not continuously
2.1
Cell Voltage (V)
3000
5.1 Introduction
1000
10
10 20 30 40 50 60 70
5.2 State of Charge Storage temperature, C
2.02
makes them the power source of choice in demanding
1.99
applications that require rapid charging. Conventional
1.96
sealed-lead batteries are not suited for this type of charging
1.93
where charge currents can be of the order of 2C10 or higher.
1.9
10 20 30 40 50 60 70 80 90 100
State of Charge, % 6.2 General
Charging CYCLON sealed-lead acid products, like charging
5.3 Storage other rechargeable batteries, is a matter of replacing the
Most batteries lose their stored energy when allowed to energy depleted during the discharge. Because this process
stand on open circuit due to the fact that the active materials is not 100% efficient, it is necessary to return more than
are in a thermodynamically unstable state. The rate of self- 100% of the energy removed during the discharge.
discharge is dependent both on the chemistry of the system The CYCLON battery cell uses the gas recombination
as well as on the temperature at which the battery is stored. principle that allows up to 100% of the oxygen generated at
All CYCLON batteries are capable of long storage without up to the C10/3 overcharge rate to be recombined to form
damage. Figure 5-2 is a plot of maximum storage time as water at the negative plate, eliminating oxygen outgassing.
a function of storage temperature. This curve shows the Hydrogen gas generation has been substantially reduced
maximum number of days at any given temperature, from by the use of pure lead-tin grid material, which has high
10C (50F) to 65C (149F), for the cell to discharge from hydrogen overvoltage. The corrosion of the positive current
a fully charged state (about 2.14 volts per cell) down to zero collecting grid has been reduced by the use of pure lead-tin.
state of charge (1.93 volts per cell). The cell should not be The amount of energy necessary for a complete recharge
allowed to discharge below 1.93 volts because of the danger depends upon how deeply the cell has been discharged, the
of damaging the performance characteristics of the cell method of recharge, the recharge time and the temperature.
permanently. Typically, between 105% and 110% of the discharged
ampere-hours must be returned for a full recharge. Thus, for
every ampere-hour discharged, one must put back between
1.05 and 1.10 ampere-hours to ensure a full recharge.
6.3 Series-parallel CYCLON Battery Systems 6.5 Fast Charging or Cyclic Charging
While there are no theoretical limits on the number of parallel A fast charge is broadly defined as a method of charge that
strings in a CYCLON battery pack, in practical situations will return the full capacity of a cell in less than four hours.
that limitation is imposed by (a) whether the application is However, many applications require a return to a high state
floating or cyclic in nature and (b) the charger design. of charge in one hour or less. Prior to the development
of CYCLON batteries, commercially available lead-acid
To avoid charge imbalance in a cyclic application, there
batteries required charging times of greater than four hours
should be no more than five (5) parallel strings. Further, the
to be brought up to a high state of charge.
minimum inrush current that the charger should be able to
provide, assuming single step constant voltage charger is Unlike conventional parallel flat plate lead-acid cells, the
5C for a five-string system. If a more sophisticated charge CYCLON battery cell uses a starved electrolyte system
algorithm such as the adaptive IUI charge profile is used, where the majority of the electrolyte is contained within a
the minimum inrush can be reduced to 2C for the five-string highly retentive fibrous glass mat separator, creating the
battery pack, allowing 0.4C charge current per string. starved environment necessary for homogeneous gas
phase transfer.
These minimum current values are critical in a cyclic
environment as the battery is on charge for only limited The gassing problem inherent in flooded electrolyte sealed-
periods of time, creating a potential for significant lead batteries that utilized alloyed lead is not evident with
undercharge. Undercharging batteries in cyclic applications the CYCLON battery system, as the extremely high purity
leads to premature capacity loss and early end of life. of lead minimizes the oxygen and hydrogen gas generation
during overcharge and any oxygen gas generated is able to
Batteries in a float application spend most of their time
recombine within the sealed cell. The high plate surface area
on float charge. This allows all strings in a series-parallel
of the thin plates used in CYCLON battery cells reduces the
system to be charged adequately, eliminating the need to
current density to a level far lower than normally seen in fast
restrict the number of parallel strings. However, it is still
charge of conventional lead-acid cells, thereby enhancing
good practice to have no more than five parallel strings,
the fast charge capabilities.
regardless of the nature of the application.
Tables 6-1 and 6-2 display the relationships between charge
rate and percent of previous discharge capacity returned
6.4 Constant Voltage (CV) Charging to the cell vs. time at 2.45 volts per cell CV charge. Prior to
Constant voltage (CV) charging is the most efficient method the recharges, the CYCLON battery cell were discharged to
of charging CYCLON battery sealed-lead products. 100% DOD.
Cyclic charging tests were conducted using a CV charger Theoretical cycling (ideal)
2.80
that had only a 1A (C10/2.5 on a 2.5Ah cell) current limit and V=0.00004T2 - 0.006T + 2.5745
Applied battery charge voltage (VPC)
the charge times shown in Table 6-3. The charge voltage, 2.70
however, was set at 2.45 VPC. The last column shows 2.60
2.40
31 to 50 8 1700
51 to 100 16 300
2.8 to reach
Time 0C (32F) 2.91 2.87 2.84 2.82
peak voltage,
2.6 25C (77F) 2.83 2.79 2.76 2.73
hours
Voltage
2.4
While CC charging is an efficient method of charging,
2.2 it requires a greater degree of control to prevent serious
2 overcharge. Continued application at rates above C10/500,
after the cell is fully charged, will be detrimental to the life
1.8
of the cell.
0 5 10 15 20 25 30
Time (Hours) At overnight charge rates (C10/10 to C10/20), the large
increase in voltage at the nearly fully-charged state is a
Figure 6-4: Constant Current Charging at 45C useful indicator for terminating or reducing the rates for a
CC charger. If the rate is reduced to between C10/1000 and
C10/500, the cell can be left connected continuously and
Voltage Profiles at 45C
Constant Current Charging
yield a float life up to 8 to 10 years at room temperature
2.8 (25C/77F).
C/5 C/15 C/20
2.6
C/10
These graphs and charts reflect data obtained from
Voltage
2.4 CYCLON cells that had been cycled three times at the
C10/5 rate. Thus, these numbers should not be treated
2.2
as specification values but rather as guidelines to follow
2 when developing or using a CC charger.
1.8
0 5 10 15 20 25 30
Time (Hours)
1.10 x C
D The quality of recharge is a critical determinant of the life
Recharge time =
C of a battery in a given cyclic application. In contrast to float
2.2V applications where more than adequate time is allowed for a
full recharge, in cyclic applications a major concern is whether
In the equation above for the recharge time using a the batteries are being fully recharged in the time available
taper charger, CD represents the discharged capacity in between discharges. If the recharge time is insufficient, the
ampere-hours while C2.2V is the charge current delivered at battery will "cycle down" or lose capacity prematurely.
2.20 VPC. The 1.10 multiplier represents the 5% to 10%
overcharge that is recommended for a complete recharge. In our experience, undercharging is a leading cause of
premature capacity loss in cyclic applications. Although
It is recommended that the charge current rate at 2.50 undercharge and overcharge are both detrimental to the
volts be between C10/50 maximum and C10/100 minimum life of a battery, the time frame over which the effects of
to insure that the battery will be recharged at normal rates either undercharge or overcharge are felt is very different.
and that the battery will not be severely overcharged if the
charger is left connected for extended time periods.
4A battery is said to have completed a cycle if it starts out from a fully charged condition, completes a discharge and is then fully recharged, regardless
of the depth of discharge.
8
7 50% drop in float life for 8C rise in Looking at the 1% cell under the 2.27 VPC column (shaded and
temperature
6 boldfaced), each 12V BC pack will require 0.0032 cubic feet of
5 airflow per hour to limit the concentration of hydrogen to 1%.
4 Since there are ten 12V packs, the ventilation system should be
3 designed for an airflow of 0.032 cubic feet per hour. This is a
2 very small amount of airflow.
33C
1
Because of the characteristics of gases and the relative difficulty
0
25 35 45 55 65 75 85
in containing them, most applications will allow for their release
Ambient temperature C
into the atmosphere. If any CYCLON batteries are being
designed into a gas-tight container, precautions must be taken
A ten year battery, such as a CYCLON battery single cell pack so that the gases produced during charge can be released into
will last for five years at 33C (91.4F) and only 2 1/2 years at the atmosphere. If hydrogen is allowed to accumulate and mix
41C (105.8F). with the atmosphere at a concentration ranging from 4% to 75%
by volume, an explosive mixture is formed that would be ignited
in the presence of a flame or spark.
Table 8-1
Hydrogen gas
evolved per battery, Cu. ft/hr. of airflow to keep hydrogen accumulation below:
12V cc/sec.
Battery 2.27 VPC 2.45VPC
2.27 VPC 2.45 VPC
1% 2% 4% 1% 2% 4%
2.5Ah (D) 0.00003 0.0003 0.0004 0.0002 0.0001 0.0038 0.0019 0.0010
4.5Ah (DT) 0.00005 0.0005 0.00064 0.00032 0.00016 0.00636 0.00318 0.00159
5Ah (X) 0.000052 0.00052 0.00066 0.00033 0.00017 0.00661 0.00331 0.00165
8Ah (E) 0.00008 0.0008 0.0010 0.0005 0.0003 0.0102 0.0051 0.0025
12Ah (J) 0.0012 0.00012 0.0015 0.0008 0.0004 0.0153 0.0076 0.0038
25Ah (BC) 0.00025 0.0025 0.0032 0.0016 0.0008 0.0318 0.0159 0.0079
Appendix A
Figure A-1: Single Cell CC Graphs to 1.67 VPC Table A-1: Amperes per Single Cell Data to 1.67 VPC
1000
Run Time D Tall D X E J BC
2 min. 24.6 34.9 44.1 55.9 63.3 164.7
100
5 min. 14.3 22.8 27.3 39.0 47.1 113.6
10 min. 8.9 14.9 17.4 26.4 33.2 76.7
Amps per cell
Table A-3: Monobloc Amperes per Cell Data to 1.67 VPC Figure A-3: Monobloc CC Graphs to 1.67 VPC
100
Run Time D Monobloc X Monobloc E Monobloc
2 min. 24.6 44.1 55.9
5 min. 14.3 27.3 39.0
Amps per MB (4V/6V)
Table A-4: Monobloc Watts per Cell Data to 1.67 VPC Figure A-4: Monobloc CP Graphs to 1.67 VPC
100
Run Time at 25C Amperes per 2.5Ah Cell Watts per 2.5Ah Cell
2 min. 21.2 37.7
5 min. 13.1 23.9
Amps or watts per cell
Figure A-6: 2.5Ah Single Cell Discharge to 1.85 VPC Table A-6: 2.5Ah Single Cell Data to 1.85 VPC
100
Run Time at 25C Amperes per 2.5Ah Cell Watts per 2.5Ah Cell
2 min. 17.0 31.0
5 min. 11.3 21.0
Amps or watts per cell
Figure A-7: 4.5Ah Single Cell Discharge to 1.75 VPC Table A-7: 4.5Ah Single Cell Data to 1.75 VPC
100
Run Time at 25C Amperes per 4.5Ah Cell Watts per 4.5Ah Cell
2 min. 30.0 50.3
5 min. 20.6 37.1
Amps or watts per cell
Table A-9: 5.0Ah Single Cell Data to 1.75 VPC Figure A-9: 5.0Ah Single Cell Discharge to 1.75 VPC
100
Run Time at 25C Amperes per 5.0Ah Cell Watts per 5.0Ah Cell
2 min. 37.2 58.6
5 min. 24.3 41.9
Amps or watts per cell
Table A-10: 5.0Ah Single Cell Data to 1.85 VPC Figure A-10: 5.0Ah Single Cell Discharge to 1.85 VPC
100
Run Time at 25C Amperes per 5.0Ah Cell Watts per 5.0Ah Cell
2 min. 29.1 53.5
5 min. 20.3 38.1
Amps or watts per cell
1000
Run Time at 25C Amperes per 8.0Ah Cell Watts per 8.0Ah Cell
2 min. 46.9 76.7
100
5 min. 34.4 59.5
Amps or watts per cell
Figure A-12: 8.0Ah Single Cell Discharge to 1.85 VPC Table A-12: 8.0Ah Single Cell Data to 1.85 VPC
1000
Run Time at 25C Amperes per 8.0Ah Cell Watts per 8.0Ah Cell
2 min. 35.8 64.0
100
5 min. 28.3 52.0
Amps or watts per cell
Figure A-13: 12.0Ah Single Cell Discharge to 1.75 VPC Table A-13: 12.0Ah Single Cell Data to 1.75 VPC
1000 Run Time at 25C Amperes per 12.0Ah Cell Watts per 12.0Ah Cell
2 min. 49.6 81.9
5 min. 40.6 72.1
100
10 min. 30.1 55.8
Amps or watts per cell
Table A-15: 25.0Ah Single Cell Data to 1.75 VPC Figure A-15: 25.0Ah Single Cell Discharge to 1.75 VPC
1000
Run Time at 25C Amperes per 25.0Ah Cell Watts per 25.0Ah Cell
2 min. 136.9 235.0
5 min. 99.8 179.1 100
Amps or watts per cell
Table A-16: 25.0Ah Single Cell Data to 1.85 VPC Figure A-16: 25.0Ah Single Cell Discharge to 1.85 VPC
Run Time at 25C Amperes per 25.0Ah Cell Watts per 25.0Ah Cell 1000
Table B-1: CYCLOND Single Cell and MB Performance Table B-2: CYCLONTall D Single Cell Performance
1.50 VPC 1.60 VPC 1.50 VPC 1.60 VPC
Run Time Amps Watts/cell Amps Watts/cell Run Time Amps Watts/cell Amps Watts/cell
2 min. 30.4 48.0 27.3 45.4 2 min. 45.4 56.7 39.3 54.8
5 min. 15.7 26.9 15.1 26.5 5 min. 26.2 39.9 24.5 39.9
10 min. 9.3 16.7 9.2 16.7 10 min. 16.1 27.6 15.6 27.6
15 min. 6.8 12.5 6.8 12.5 15 min. 11.9 21.4 11.6 21.6
20 min. 5.4 10.1 5.4 10.1 20 min. 9.5 17.6 9.3 17.6
30 min. 3.9 7.4 3.9 7.4 30 min. 6.8 13.1 6.7 13.1
45 min. 2.8 5.35 2.8 5.3 45 min. 4.8 9.5 4.8 9.4
1 hr. 2.2 4.2 2.2 4.2 1 hr. 3.8 7.4 3.7 7.4
2 hr. 2.0 4.0 2.0 4.0
2 hr. 1.2 2.35 1.2 2.3
3 hr. 1.4 2.8 1.4 2.7
3 hr. 0.80 1.65 0.80 1.6
4 hr. 1.1 2.1 1.1 2.1
4 hr. 0.65 1.3 0.60 1.3
5 hr. 0.90 1.7 0.90 1.7
5 hr. 0.50 1.0 0.50 1.0 8 hr. 0.60 1.1 0.55 1.1
8 hr. 0.30 0.70 0.30 0.70 10 hr. 0.50 0.90 0.45 0.90
10 hr. 0.28 0.54 0.27 0.54 20 hr. 0.24 0.46 0.24 0.46
20 hr. 0.14 0.28 0.14 0.28
Table B-3: CYCLONX Single Cell and MB Performance Table B-4: CYCLONE Single Cell and MB Performance
1.50 VPC 1.60 VPC 1.50 VPC 1.60 VPC
Run Time Amps Watts/cell Amps Watts/cell Run Time Amps Watts/cell Amps Watts/cell
2 min. 57.5 67.4 50.1 65.2 2 min. 70.6 92.6 63.1 90.5
5 min. 30.9 44.6 29.3 45.0 5 min. 45.3 68.1 42.3 67.2
10 min. 18.5 30.4 18.2 31.0 10 min. 29.2 47.9 28.0 47.4
15 min. 13.5 23.5 13.4 23.5 15 min. 21.8 37.4 21.1 37.0
20 min. 10.8 19.4 10.7 19.6 20 min. 17.5 30.8 17.1 30.6
30 min. 7.7 14.5 7.7 14.6 30 min. 12.6 23.0 12.4 22.8
45 min. 5.5 10.6 5.5 10.6 45 min. 8.9 16.7 8.8 16.6
1 hr. 4.3 8.4 4.3 8.3 1 hr. 6.9 13.2 6.9 13.1
2 hr. 2.3 4.6 2.3 4.5 2 hr. 3.7 7.2 3.7 7.2
3 hr. 1.6 3.2 1.6 3.1 3 hr. 2.5 5.0 2.5 5.0
4 hr. 1.2 2.4 1.2 2.4 4 hr. 1.9 3.8 1.9 3.8
5 hr. 1.0 2.0 1.0 1.9 5 hr. 1.6 3.1 1.6 3.1
Publication No: US-CYC-AM-007 - April 2008 - Subject to revisions without prior notice. E.&O.E.
8 hr. 0.60 1.3 0.60 1.2 8 hr. 1.0 2.0 1.0 2.0
10 hr. 0.50 1.0 0.50 1.0 10 hr. 0.80 1.6 0.80 1.6
20 hr. 0.30 0.50 0.30 0.50 20 hr. 0.40 0.80 0.40 0.80
Table B-5: CYCLON J Single Cell Performance Table B-6: CYCLONBC Single Cell Performance
1.50 VPC 1.60 VPC 1.50 VPC 1.60 VPC
Run Time Amps Watts/cell Amps Watts/cell Run Time Amps Watts/cell Amps Watts/cell
2 min. 82.9 106.9 74.0 103.8 2 min. 216.7 324.7 188.4 296.4
5 min. 55.8 84.4 51.8 83.8 5 min. 133.8 219.9 124.0 210.4
10 min. 37.2 61.9 35.4 62.2 10 min. 85.2 148.2 81.5 144.9
15 min. 28.4 49.2 27.3 49.7 15 min. 63.5 113.7 61.6 112.1
20 min. 23.1 41.1 22.3 41.6 20 min. 51.0 92.9 49.8 92.0
30 min. 17.0 31.0 16.5 31.5 30 min. 36.9 68.8 36.3 68.3
45 min. 12.3 22.9 12.0 23.3 45 min. 26.3 50.0 26.1 49.8
1 hr. 9.6 18.2 9.5 18.5 1 hr. 20.6 39.5 20.4 39.3
2 hr. 5.3 10.1 5.2 10.3 2 hr. 11.2 21.8 11.1 21.7
3 hr. 3.7 7.0 3.6 7.1 3 hr. 7.7 15.3 7.7 15.2
4 hr. 2.8 5.4 2.8 5.4 4 hr. 5.9 11.8 5.9 11.7
5 hr. 2.3 4.4 2.3 4.4 5 hr. 4.9 9.6 4.8 9.6
8 hr. 1.5 2.8 1.5 2.9 8 hr. 3.2 6.3 3.1 6.2
10 hr. 1.2 2.3 1.2 2.3 10 hr. 2.6 5.2 2.6 5.1
20 hr. 0.60 1.2 0.60 1.2 20 hr. 1.4 2.8 1.4 2.8
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