VRLA Battery Charging Guide Aims to Extend Lifespan

Have you ever been confused about charging your Discover Valve Regulated Lead Acid (VRLA) batteries? Uncertain charging durations, inconsistent results, and concerns about potential damage to battery lifespan are common challenges. This comprehensive guide will explain the correct charging methods for VRLA batteries, helping you optimize performance and eliminate charging-related concerns.

Charging your Discover VRLA battery involves more than simply connecting it to a power source. Charging duration depends on four primary factors:

Imagine the battery as a water reservoir. The deeper the discharge, the more "water" needs to be replenished, resulting in longer charging times. Understanding your battery's discharge level is essential for estimating charging duration.

Temperature significantly impacts battery chemical reactions. Both extremely high and low temperatures reduce charging efficiency. The ideal charging temperature range is between 20°C to 25°C. Charging outside this range not only prolongs charging time but may also cause battery damage.

The charger serves as the battery's "power station." Its power rating and efficiency directly affect charging speed. Higher-powered, more efficient chargers complete the process faster. Selecting a charger that matches your battery's capacity is crucial for optimal performance.

A battery's age and condition influence its charging capacity. As batteries age, internal resistance increases, reducing charging efficiency and extending charging time. Issues like sulfation or corrosion also affect charging. Regular maintenance checks help identify and resolve problems early, extending battery life.

Charging current directly impacts both charging speed and battery longevity. For Discover batteries, the recommended charging current is:

• Initial charging current: 15% to 30% of the battery's C20 capacity

C20 capacity refers to the battery's discharge capacity over 20 hours to cutoff voltage. For example, a 100Ah battery would require an initial charging current between 15A and 30A.

VRLA battery charging typically occurs in three phases: constant current, constant voltage, and float charging. Understanding each phase helps optimize the charging process.

During this phase, the charger delivers constant current to quickly replenish energy. Typically bringing the battery from 0% to 95% State of Charge (SOC), this stage accounts for approximately 60% of total charging time.

When the battery reaches 95% SOC, the charger switches to constant voltage mode with decreasing current. This final 5% charge requires about 40% of total charging time, highlighting the importance of patience during this critical stage.

After full charge, the charger maintains the battery with lower voltage to compensate for self-discharge, prevent sulfation, and extend battery life. For long-term storage, periodic float charging helps maintain battery health.

The most reliable method for verifying a VRLA battery's charge status involves measuring its Open Circuit Voltage (OCV) with a voltmeter.

Measurement procedure: Disconnect all loads and chargers, let the battery rest for 24 hours, then measure voltage across the terminals.

Reference values: The following table shows State of Charge versus OCV for different battery types.

Note: These values apply to 12V batteries. For 6V batteries, divide by 2; for individual cells, divide by 6. Accurate OCV measurements require 24 hours without charging or discharging.

Both overcharging and undercharging significantly reduce battery lifespan and should be avoided.

Chronic undercharging leads to positive plate corrosion, lead sulfate accumulation, and plate shedding, ultimately shortening battery life. Undercharged batteries work harder, accelerating aging. It also causes acid stratification, reducing capacity and making batteries more susceptible to deep discharge damage.

Overcharging generates excessive heat, causing electrolyte breakdown, gas production, and water loss. Severe cases may lead to swelling, deformation, or even explosion. Always use chargers with overcharge protection and carefully monitor charging parameters.

If OCV is below 75%, charge the battery first.

• For adjustable loads: Set to three times the 20-hour discharge rate for 15 seconds. Voltage should remain above 9.6V.
• For batteries with CCA (Cold Cranking Amps) ratings: Apply half the CCA rating for 15 seconds, maintaining voltage above 9.6V.
• For more rigorous testing: Apply full CCA rating for 30 seconds or 5-7 times the AH rating for 30 seconds, maintaining voltage above 7.2V.

If voltage drops below 9.6V (or 7.2V for full CCA test), recharge and retest. If the second test fails again, replace the battery.

Beyond proper charging techniques, these practices help extend battery life:

• Avoid deep discharges: Recharge when capacity remains above 20%.
• Conduct regular inspections: Check for swelling, leaks, or deformation. Monitor voltage to assess health.
• Maintain cleanliness: Keep terminals and surfaces free from dirt and corrosion.
• Store properly: For long-term storage, fully charge batteries and keep in cool, dry locations with periodic float charging.

By following these guidelines, you can optimize your Discover VRLA battery's performance, ensure reliable operation, and maximize its service life.