MK Battery 8G27-DEKA Manual

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Valve-Regulated Lead-Acid (VRLA)

Gelled Electrolyte (gel) and Absorbed Glass Mat (AGM) Batteries

TECHNICAL MANUAL

EAST PENN Expertise and American Workmanship Quality System Certified to ISO 9001

Introduction

Valve-regulated lead-acid (VRLA) technology encompasses both

gelled electrolyte and absorbed glass mat (AGM) batteries. Both types

are valve-regulated and have significant advantages over flooded lead-

acid products.

More than a decade ago, East Penn began building valve-regulated

batteries using tried and true technology backed by more than

50 years experience. East Penn’s unique computer-aided manufactur-

ing expertise and vertical integration have created a product that is

recognized as the highest quality, longest lived VRLA battery

available from any source.

East Penn’s gel and AGM batteries are manufactured to tough quality

standards. East Penn manufactures high power gel and AGM batteries

with excellent performance and life.

Applications

VRLA batteries can be substituted in virtually any flooded lead-acid

battery application (in conjunction with well-regulated charging), as

well as applications where traditional flooded batteries cannot be

used. Because of their unique features and benefits, VRLA batteries

are particularly well suited for:

Deep Cycle, Deep Discharge Applications

• Marine Trolling • Electronics • Sailboats

• Electric Vehicles • Wheelchairs • Golf Cars

• Portable Power • Floor Scrubbers

• Personnel Carriers • Marine & RV House Power

• Commercial Deep Cycle Applications

Standby and Emergency Backup Applications

• UPS (Uninterrupted Power Systems) • Cable TV

• Emergency Lighting • Computer Backup • Solar Power

• Telephone Switching • Village Power

Unusual and Demanding Applications

• Race Cars • Air-transported Equipment

• Off-road Vehicles • Wet Environments

• Marine & RV Starting • Diesel & I.C.E. Starting

What is a gel battery?

A gel battery is a lead-acid electric storage battery that:

• is sealed using special pressure valves and should never be

opened.

• is completely maintenance-free.*

• uses thixotropic gelled electrolyte.

• uses a recombination reaction to prevent the escape of

hydrogen and oxygen gases normally lost in a flooded

lead-acid battery (particularly in deep cycle applications).

• is non-spillable, and therefore can be operated in virtually any

position. However, upside-down installation is not recommended.

* Connections must be retorqued and the batteries should be cleaned periodically.

What is an AGM battery?

An AGM battery is a lead-acid electric storage battery that:

• is sealed using special pressure valves and should

never be opened.

• is completely maintenance-free.*

• has all of its electrolyte absorbed in separators consisting

of a sponge-like mass of matted glass fibers.

• uses a recombination reaction to prevent the escape of

hydrogen and oxygen gases normally lost in a flooded

lead-acid battery (particularly in deep cycle applications).

• is non-spillable, and therefore can be operated in virtually

any position. However, upside-down installation is not

recommended.

* Connections must be retorqued and the batteries should be cleaned periodically.

How does a VRLA battery work?

A VRLA battery is a “recombinant” battery. This means that the

oxygen normally produced on the positive plates of all lead-acid

batteries is absorbed by the negative plate. This suppresses the

production of hydrogen at the negative plate. Water (H

O) is

produced instead, retaining the moisture within the battery.

It never needs watering, and should never be opened as this

would “poison” the battery with additional oxygen from the air.

Opening the battery will void the warranty.

What are the differences between gel

batteries and absorbed glass mat

(AGM) batteries?

Both are recombinant batteries. Both are sealed valve-regulated

(SVR) – also called valve-regulated lead-acid (VRLA). AGM batteries

and gel batteries are both considered “acid-starved”. In a gel

battery, the electrolyte does not flow like a normal liquid.

The electrolyte has the consistency and appearance of petroleum

jelly. Like gelled electrolyte batteries, absorbed electrolyte batteries

are also considered non-spillable – all of the liquid electrolyte is

trapped in the sponge-like matted glass fiber separator material.

The “acid-starved” condition of gel and AGM batteries protects

the plates during heavy deep-discharges. The gel battery is more

starved, giving more protection to the plate; therefore, it is better

suited for super-deep discharge applications.

Due to the physical properties of the gelled electrolyte, gel battery

power declines faster than an AGM battery’s as the temperature

drops below 32ºF. AGM batteries excel for high current, high power

applications and in extremely cold environments.

Summary of content (16 pages)

PAGE 1
TECHNICAL MANUAL Valve-Regulated Lead-Acid (VRLA) Gelled Electrolyte (gel) and Absorbed Glass Mat (AGM) Batteries EAST PENN Expertise and American Workmanship Quality System Certified to ISO 9001 Introduction • is non-spillable, and therefore can be operated in virtually any position. However, upside-down installation is not recommended. Valve-regulated lead-acid (VRLA) technology encompasses both gelled electrolyte and absorbed glass mat (AGM) batteries.
PAGE 2
What is the difference between VRLA batteries and traditional wet batteries? Can our VRLA batteries be used as starting batteries as well? Wet batteries do not have special pressurized sealing vents, as they do not work on the recombination principle. They contain liquid electrolyte that can spill and cause corrosion if tipped or punctured. Therefore, they are not air transportable without special containers. They cannot be shipped via UPS or Parcel Post or used near sensitive electronic equipment.
PAGE 3
CHART A Independent Laboratory Testing BCI 2-Hour Life Group Size “27” Batteries East Penn Gel and AGM vs. Competitor This chart compares the cycles run until the battery capacity dropped to 50% of the 15th cycle’s capacity (on discharges at the 2-hour rate to a 10.5-volt cutoff). East Penn AGM East Penn Gel CHART B Charging Current vs.Charging Time Shown is the current needed to charge a battery from 0% to 90% state of charge in a given time.
PAGE 4
CHART C VRLA Battery Voltage During Constant Current Discharge Battery Voltage Voltage vs. Percent Discharged CHART D Gel Percent Cycle Life vs. Recharge Voltage This chart shows the effect on life of overcharging a gel battery. (e.g.: Consistently charging at 0.7 volts above the recommended level reduces life by almost 60%!) % of Cycle Life (B.C.I.
PAGE 5
What are the features and benefits that make East Penn’s VRLA batteries unique? Exclusive Computerized Gel Mixing Proper gel mixing is critical to life and performance. Consistency in mixing means consistent reliability. We have designed and built the newest, state-of-the-art gel battery manufacturing facility in the world. An example is our proprietary computerized gel mixing operation. East Penn Expertise East Penn builds VRLA batteries to the highest standards.
PAGE 6
Ultrapremium AGM glass mat separators loss is harmful to the battery and is evident by black posts, which are caused by sulfuric acid fumes escaping from the battery through and around the lead posts and bushings. These fumes can cause corrosion and can damage sensitive electronic equipment. Glass mat separator properties can vary considerably. East Penn uses glass mat engineered to have an ideal balance of properties— i.e. absorbency, compressibility, puncture resistance and electrical resistance.
PAGE 7
Proprietary Case, Cover, and Pressure Vent State-of-the-Art Technology We design and mold our own rugged polypropylene cases, vents and covers in our on-site, state-of the-art plastics molding facility. This provides ultimate control of our high performance designs, quality and delivery to our manufacturing plant, assuring you the highest quality battery and most reliable service.
PAGE 8
How do East Penn’s VRLA battery features compare with other types of batteries? FEATURE EPM GEL OTHER GEL EPM AGM 0THER AGM ALL WET CELLS 1. EPM Expertise YES NO YES NO EPM ONLY 2. Spillproof and Leakproof YES YES YES YES NO 3. Sealed Valve-Regulated YES YES YES YES NO 4. Ultra-Premium Sealing Valve YES NO YES NO NO 5. Exclusive Gel Formula YES NO NO NO NO 6. Deep Discharge Protection YES YES YES YES NO 7.
PAGE 9
Answers to the Most Frequently Asked Questions NOTE: Before reviewing this section, be sure you understand the difference between gel, AGM, and flooded batteries.
PAGE 10
Why can’t VRLA batteries be opened? • Our VRLA batteries are protected against deep discharge because they are “acid-starved.” This means that the battery uses the power in the acid before it uses the power in the plates. Therefore, the plates are never subjected to destructive ultra-deep discharges. VRLA (Valve-Regulated Lead-Acid) batteries, sometimes called SLA (Sealed Lead-Acid) batteries or SVR (Sealed Valve-Regulated) batteries work on a recombination principle.
PAGE 11
Gel Charge and Float Voltages at Various Temperature Ranges Follow these tips for the longest life: • Avoid ultra-deep discharges. • Don’t leave a battery at a low stage of charge for an extended length of time. Charge a discharged battery as soon as possible. • Don’t cycle a battery at a low state of charge without regularly recharging fully.
PAGE 12
FULLY CHARGED Specific Gravity 1.265 FULLY DISCHARGED Specific Gravity below 1.225 Specific Gravity 1.190 Specific Gravity 1.120 Typical Charging Time vs. 90% and 100% State of Charge 60% of time State of 0% Charge EXAMPLE: s POS = PbO2 NEG = Pb ACID = H2SO2 As battery discharges, the sulfate from the electrolyte forms on the plates.
PAGE 13
How can continual undercharging harm a battery? What is a thermal runaway? The appropriate charge voltage depends on the battery temperature (see page 11). A warmer battery requires a reduced voltage. If the voltage is not reduced, current accepted by the battery increases. When the current increases, the heating increases. This can continue in a loop feeding on itself with the battery temperature and charging current rising to destructive levels.
PAGE 14
e. At the end of charge (when the current is very low or goes to zero) check and record the voltage. Note that the charger may have turned off by then. f. The disconnected battery should be at 100% or above after a 24 hour rest. During the charging time, the charger should not have exceeded the limit (except for occasional, brief pulses). This indicates that the charger is working properly. The valves only let gas out, never in. A partial vacuum can form within a sealed battery under various circumstances.
PAGE 15
Also, when protected against short circuits and securely braced/ blocked, our VRLA batteries “are not subject to any other requirements of 49 CFR Parts 171-180…” for shipping. g. Spray exposed terminals and connectors with several coats of battery terminal corrosion protection spray. (Mask surrounding areas to protect against overspray.) h. For batteries which may be exposed to very wet environments (e.g. bilge mounted batteries) total encasement of the exposed terminals and connectors is necessary.
PAGE 16
To properly recharge, a sophisticated “battery isolator” should be installed. Otherwise, one battery will be continually overcharged and the other undercharged in a dual-voltage set-up. IMPORTANT: Do not install any type of battery in a completely sealed box or enclosure. In the event of overcharging, the potentially explosive gasses must be allowed to escape. During recharge, the current (amps) is split between the batteries.