MK Battery Manual

5
What are the features and benefits that
make East Penn’s VRLA batteries unique?
East Penn Expertise
East Penn builds VRLA batteries to the highest standards. Our manu-
facturing process features improved controls using state-of-the art
computers and the latest manufacturing technology and equipment.
Therefore, the VRLA batteries produced by East Penn consistently
meet the highest quality performance and life standards.
Ultrapremium Sealing Valve
A critical feature of any VRLA battery, gelled or absorbed, is the quali-
ty of the sealing valve. Not only must the valve keep the cell pressur-
ized and safely release excessive pressure and gas due to overcharg-
ing, but it must also keep the cell from being contaminated by the
atmosphere. Oxygen contamination will discharge a VRLA battery
and eventually ruin the battery.
Our valves are UL recognized and 100% tested after manufacturing.
The benefit is reliable performance and long life.
Spillproof and Leakproof
A major advantage of VRLA batteries is their spillproof and leakproof
feature. However, all VRLA batteries are not created equal in their
degree of non-spillability. Some manufacturer’s AGM batteries are
unevenly filled. Over-saturation of the separators leaves liquid elec-
trolyte that could spill. Under-saturation could lead to premature failure.
Some gels do not set properly; they remain liquid and can leak or spill.
Our exclusive gel electrolyte is formulated, mixed and controlled to
assure proper “set” in every battery. East Penn’s computer-controlled
gel mixing and filling equipment ensures homogenization of the mix.
This assures a gel battery that will not spill or leak. This feature allows
our gel cell to be operated in virtually any position. However, we do
not recommend an upside-down orientation.
The AGM filling process assures that each cell is saturated with the
maximum amount of electrolyte that can be held by the separators,
without leaving excess electrolyte that could spill or leak.
Exclusive Gel Formula
The gelled electrolyte is another critical element in this type of battery.
Our gelled electrolyte contains sulfuric acid, fumed silica, pure
demineralized, deionized water, and a phosphoric acid additive.
The phosphoric acid is a key reason that our batteries deliver
dramatically longer cycle life than leading gel competitors and
3 times longer cycle life than traditional wet cells.
Exclusive AGM Electrolyte
Our AGM electrolyte contains high purity sulfuric acid and absolutely
pure totally demineralized, deionized water to increase battery
performance. Since the designs are “acid-starved” to protect the
plates from deep discharge, the acid concentration can drop to nearly
zero during an extremely deep discharge. Substances that will not
dissolve in acid may become soluble when the concentration drops
this low. Upon recharge, these dissolved substances crystallize out
of the electrolyte, potentially destroying the battery. Our electrolyte
prevents these events.
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.
Our exclusive formula is mixed using computer control in every stage
of the process. Computer control delivers superior consistency for
gel battery performance that is unequaled.
Our temperature-controlled process and specially designed equip-
ment assure a homogenous gel. It is important to note that our
equipment was designed by our engineers specifically for gel mixing…
even down to the contour of the tank bottoms and feed pipe loca-
tions. No other battery manufacturer has comparable equipment.
Multi-Staged Filling/Vacuuming Operation
Most other manufacturers fill their gel cells in a one step process,
vibrating the battery with hopes of releasing most of the air pockets.
This system is less than perfect and leaves voids or air pockets at
the critical gel-to-plate interface. These voids are non-reactive and
reduce overall battery performance.
Our process fills and vacuums each cell several times. This multi-step
process assures complete evacuation of air and complete gel-to-
plate interface. Our computerized process also weighs every battery
before and after filling as a check for proper gel levels. The benefit is
more power-per-pound of battery.
Our AGM topping process assures that the maximum retainable elec-
trolyte quantity is held within the battery separators, without leaving
any unabsorbed liquid to spill or leak.
Tank Formed Plates
East Penn is the only battery manufacturer that uses tank formation
to activate the battery plates. This process guarantees a fully formed
and voltage matched plate. The extra handling of the plates provides
an additional inspection step in the process to verify plate quality.
Ultrapremium, Gel Glass Mat, Double Insulating Separators
Another critical component is the separator, which isolates the
positive from the negative plate. The separator must allow
maximum charge flow between the plates for maximum performance.
Separator failure is a leading cause of warranty claims
and customer dissatisfaction.
East Penn uses an ultrapremium grade separator in our gel batter-
ies. We believe that this expense (which is 5 to 6 times higher than
other types) is worth the benefits of extended life and performance:
• The fiberglass mats embed themselves into the surface of
the plates, acting like reinforcing rods in concrete. This
extra reinforcement locks the active material onto the plate
for longer life and extended performance.
• The ultra-clean separators have no oil contamination
or other impurities. Therefore, resistance is low and
battery performance is high.
• Excellent porosity allows maximum charge flow,
which means more power-per-pound.
• Superior resistance to oxidation dramatically reduces
separator failure, which extends life.
• Our separators are especially suited for gel batteries,
while others use separators designed for flooded
automotive batteries.