VRLA Battery Symptoms and Solutions

1. The following inspections, symptoms and solutions are provided for reference.
The actual judgments should be performed by Quality Assurance Department.
2. For assurance of the optimum reliability it is necessary to perform the
recommended periodic maintenance. The recommended inspections should be
performed at least on a quarterly basis.
3. The recommended periodic inspections can be performed either manually or via
automated monitoring systems.
4. The recommended periodic inspections are designed to determine the gradual
degradation of the system's capacity and to detect any abnormal system or
individual battery condition which could impact system reliability.
 VRLA Battery Visual Inspection
Symptom Possible Causes Possible Results
Cover/container
Handling or impact damage
cracked
Ignition of cell's internal
gases due to external
source, fusing of internal
Cover/container conductive path, or internal
explosion spark due to shorting. This
potential exists for batteries
left in service beyond their
useful service life.
Signs of Crack in container causes
overheating on leaking of electrolyte to
battery grounded rack, etc. Ground
container fault
Thermal runaway possible
caused by a high
Permanently temperature environment,
deformed overcharging, excessively
(swollen) high recharge current,
container shorted cells, ground fault
or a combination of these
causes
Possibly caused by a high
temperature environment,
overcharging or an
Rotten egg odor
excessively high recharge
current, shorted cells of a
combination of these causes
Connections were hot due
to excessive resistance
Melted grease caused by a loose
at terminal connection, dirty contact
surfaces or corrosion within
the connection
These is possibly either
residual electrolyte from
manufacturing or electrolyte
Corrosion at
leaking from the battery
terminals
terminal seal that is
attacking the inner-unit
connector
Corrective Actions
Cell dry out or ground
fault. Potential internal Replace damaged unit
gas ignition
Personal injury and
Replace damaged unit
equipment damage at
and evaluate any
time of explosion.
additional batteries
Failure to support load.
Could result in
personnel hazard due
to conductive path to Clear the grounded fault
rack, etc. and replace defective
Could result in smoke unit. Evaluate balance of
or a battery fire string
Could result in a
thermal runaway
Could result in the
emission of hydrogen Replace the battery
sulfide which is system and correct the
detectable as a rotten items leading to the
egg odor, battery fire thermal runaway
and the inability to condition
support the load
Replace the battery
Odor is a product of system and correct the
extended thermal items leading to the
runaway thermal runaway
condition
Excessive voltage drop
perhaps leading to
Clean and reassemble
short operating time or
the connection if
damaged terminals. In
undamaged. Replace any
extreme case, could
battery with damaged
lead to melted
terminals
terminal and ignition
of the battery cover
Disassemble connection,
clean, coat connecting
surfaces and terminal
Increased connection
area and seal with
resistance in the
oxidation grease and
connection, lead to
appropriately reassemble
increased heating and
the connection. If
voltage drop at high
leakage about the
rate discharge
terminal area is obvious,
the battery should be
replaced.
 VRLA Battery Capacity Test Results
Symptom Possible Causes Possible Results Corrective Actions
Normal wear out Eventual failure to Replace battery
Reduced run time at
support the load system when at 80% of
77°F with smooth
followed by potential rated capacity or
voltage decline
for shorted cells. before
Individual low capacity Reversed cells during Replace the isolated
Reduced run time at
cells discharge. Reversed low capacity batteries
77°F with steep
cells will become very
voltage decline or
hot and will not
voltage plateaus
recharge
Battery is cold Warm up the battery
Cabling is too small Excessive voltage drop Add parallel cables
High resistance Excessive voltage drop Clean and reassemble
Excessive initial connections connections
voltage drop even to Battery is undersized Add required parallel
the point of dropping strings
load in the first several Shorted cells Cells will become hot, Replace isolated units
Seconds could develop thermal with shorts and
runaway, internal evaluate entire string
arcing could result in
explosion
 VRLA Battery DC Voltage Inspections
Symptom Possible Causes Possible Results Corrective Actions
System float voltage Overcharging will cause
greater than 2.3 V/cell Charger output excessive gassing and Reset the charge
at an average voltage set drying of the output voltage to the
temperature of 77°F incorrectly electrolyte, potential of recommended value
(25°C) thermal runaway
Undercharging will Reset the charger
result in gradual loss of output voltage to the
operation time and recommended value.
capacity with successive
System float voltage Charger output discharge cycles. If Equalize the battery
less than an average of voltage set allowed to persist, an system for 48 to 72
2.25 V/cell incorrectly irreversible level of lead hours and perform a
sulfate will develop on capacity test. If loss is
the plates with the permanent, replace
result of a permanent the total battery
loss of capacity. system
Overcharging will cause
System equalize excessive gassing and
Charger equalization Reset the charger
voltage is greater than drying of the electrolyte
voltage is set output voltage to the
an average of 2.45 and will contribute to
incorrectly recommended value
V/cell potential thermal
runaway
If possible, reset the
Equalization and boost charger output voltage
System equalize Charger equalization
charging will be less to the recommended
voltage is less than an voltage is set
effective and will value or accept a
average of 2.45 V/cell incorrectly
require extended time longer equalization
time
Individual battery float
Potentially the Reduced operating time
voltage less than an
individual battery has under a load, increased
average of 2.2 V/cell
a shorted cell. This float current, heating Replace the individual
(13.3 VDC for 6 cell
could be verified with during discharge, battery
battery, 11.1 VDC for 5
an impedance or contributes to potential
cell battery, 6.6 VDC
conductance check thermal runaway
for 3 cell battery)
Potentially there may
be an open cell in the
Individual battery float
individual battery.
voltage greater than Failure to support the
This can be
an average of 2.42 load. Could result in an
confirmed by Replace the individual
V/cell (14.5 VDC for 6 internal arc which could
checking for zero battery
cell battery, 12.1 for 5 ignite the gasses within
float current or
cell battery, 7.3 for 3 the cell
checking for a very
cell battery)
high impedance of
the battery.
DC voltage measured Personnel shock hazard
between either of the Damaged battery which could result in
Determine the source
battery system output container allowing serious injury or
of the ground fault
terminals and ground electrolyte to leak electrocution
and replace the
(rack) or a ground fault out to the grounded Potential burning of the battery
indicated by automatic surface (rack) container at damaged
monitoring equipment area or battery fire
 VRLA Battery Float Charging Current Inspections
Symptom Possible Causes Possible Results Corrective Actions
Failure to support the
load. If an internal arc
should occur during
A battery or
discharge, it could
connection in the
ignite the internal
series string is open. Replace the battery
gasses of the cell.
Float current to the This can be verified via with the open cell or
If there is an
string is zero the float voltage or repair the open/loose
open/loose
impedance check of external connection.
connection in the
the individual
external conductive
batteries.
path, it could damage
the termination under
load.
Batteries are not yet Not at 100% of
fully recharged capability
Batteries are above Leads to thermal
77°F (25°F) runaway
Potentially shorted Leads to thermal
Float current current Determine the specific
cells in battery runaway
exceeds 0.03CA at cause and take the
Thermal runaway
77°F (25°C) at float necessary corrective
results in eventual
charge. Depending on the action
meltdown of the
degree, the battery
battery and the
may be entering or in
potential of hydrogen
thermal runaway
sulfide emissions and
fire
AC ripple current
Excessive AC ripple
exceeds 5 amperes per Poor filtering of the Improve the charger
current will result in
100 Ah rated battery charger output filtering
battery heating
capacity

VRLA Battery Temperature Inspections

Symptom Possible Causes Possible Results Corrective Actions
Elevated room Lack of adequate air Cool the room or accept
Reduced battery life
temperature conditioning/ventilation reduced battery life
Reduced life and
Elevated room Improve room air
potential thermal
temperature conditioning
runaway
Reduced life and Improved cabinet
Inadequate cabinet
potential thermal ventilation and
ventilation
runaway temperature
Elevated battery
Can be normal if not
temperature
Discharge-Charge cycle exceeding 18°F (10°C) Limit recharge current
increase
AC ripple current
Reduced life and Determine the cause of the
greater than 5 amperes
potential thermal excessive AC ripple current
rms/100 Ah battery
runaway and correct
capacity
High charging voltage Limit recharge current
Reduce to within
High current The combination can
specifications
recharge Shorted cells lead to thermal runaway
Reduce shorted cells and
evaluate total string
 VRLA Battery High Rate 10 Second Load Test
Symptom Possible Causes Possible Results Corrective Actions
Battery could not be
Terminal voltage is
fully charged or is an
marginally below the
older battery that has Could have a reduced Fully recharge the
minimum voltage
been in service and has operating time filtering
specified for 10
a somewhat lower
Second point
capacity
Battery is discharged or
there is deterioration of
Terminal voltage is the conductive path, Reduced operating
significantly below plate grid, active time Charge and reset
the minimum material or electrolyte battery or replace as
voltage specified for volume required
10 Second point Conductive to thermal
Shorted
runaway
Open cells Will not support load

VRLA Battery Connection Hardware Resistance / Tightness Inspection

Symptom Possible Causes Possible Results Corrective
Actions
Repetitive cycles resulting in
Loose connections
heating and cooling of
can result in heat
connection can result in
damaged or melted
relaxation of torque and an
Connection resistance terminals during high
increase in connection Re-torque the
increase of 20% or rate discharge
resistance connection as
more from original
Excessive voltage required
value Contamination within the
drop during high rate
connection can result in
discharge resulting in
corrosion and high terminal
reduced operating
resistance
time
Repetitive cycles resulting in
Loose connections
Connection hardware heating and cooling of
can result in heat Re-torque the
tightness is less that connection can result in
damaged or melted connection as
the specified relaxation of torque and an
terminals during high required
re-torque value increase in connection
rate discharge
resistance
Battery is discharged or there
When new is deterioration of the
Reduced operating
impedance/resistance conductive path, plate grid,
time Charge and reset
increases by 50% active material or electrolyte
battery or replace as
from original value or volume
required
conductance declines Conductive to
Shorted cells
to 50% thermal runaway
Open cells Will not support load
 VRLA Battery AC Ripple Voltage Inspections
Symptom Possible Causes Possible Results Corrective
Actions
AC ripple (p-p) Excessive AC ripple could
voltage on the cause the battery to cycle at
Improve the
system is greater Poor filtering of the the ripple frequency and
charger output
than 4% of the charger output result in heating and
filtering
value of the DC deterioration of the active
float voltage plate material
Battery with the high AC
ripple voltage has a Reduce operating time
Individual battery
proportionately higher
in string exhibits Verify the
impedance and should be
AC ripple voltage battery
further evaluated for
of twice that of condition and
performance. Subject Potential conditions could be
the other typical replace as
battery could have a conductive to thermal
batteries in the required
deteriorating conductive runaway
string
path or a dry, shorted or
open cell