Regal Electro VALEN Installation And Operating Instructions Manual

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TOPIN 6-12V BATTERIES

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INSTRUCTION AND OPERATIONS MANUAL

VALEN GEL 6-12V

TABLE OF CONTENTS

SECTION

CONTENT

PAGE

SECTION

CONTENT

PAGE

1.0

GENERAL INFORMATION

5.4

Electrical Connections

1.1

Battery Characteristics

5.4.1

Cabling Recommendations

5.4.2

Terminal Preparation

2.0

SAFETY INFORMATION

5.4.3

Connector Installation

2.1

General Information

5.4.4

Voltage Checks

2.2

Sulphuric Acid

5.4.5

Battery to Charger Connection

2.3

Gassing

5.4.6

Paralleling of Batteries

2.4

Electrical Shock

6.0

OPERATION

3.0

RECEIPT OF EQUIPMENT

6.1

Initial Charge

3.1

Delivery Inspection

6.2

Float Voltage

3.2

Hidden Damage

6.2.1

Float Voltage Requirements

6.2.2

Float Temp. Compensation

4.0

STORAGE

6.3

Maximum Charge Current

4.1

General

6.4

Recharge

4.2

Short Term Storage

6.5

Equalisation Charge

5.0

INSTALLATION PROCEDURES

7.0

STORAGE

5.1

Battery Location

5.1.1

Temperature

8.0

MAINTENANCE & RECORDS

5.1.2

Temperature Variation

8.1

General Maintenance

5.1.3

Ventilation

8.2

General Records

5.1.3.1

Battery Temperature Variation

8.2.1

Installation Records

5.1.3.2

Ventilation and Gassing

8.2.2

Maintenance Records

5.1.4

Floor Loading

5.1.5

Seismic Considerations

9.0

CAPACITY TESTING

5.2

Unpacking

9.1

General

5.3

Installation

9.2

Test Procedures

5.3.1

General

5.3.2

Location Layout

10.0

BATTERY MAINTENANCE

5.3.3

Horizontal Module Installation

REGISTER

5.3.4

Vertical Module Installation

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SECTION 1 - GENERAL INFORMATION

1.1 VALEN 2V GEL Battery Characteristics

The VALEN 2V GEL Battery is a sealed, valve­regulated lead-acid recombinant, low maintenance
battery designed for stationary or cycling
applications. This type of battery has no special
ventilation or handling requirements. Since the
electrolyte in the battery is immobilised, the
batteries are considered dry and can be handled
and shipped accordingly.

SECTION 2 - SAFETY INFORMATION

2.1 General Information
Lead acid batteries require care in installation and
maintenance. Unsafe installation or maintenance
procedures can cause severe injury or death. Electrical
shock or burns, acid burns and fire can result if proper
safety precautions are not followed. The following
precautions apply to all battery installation and
maintenance work. For more information see the
following sections.

Disconnect all power before attempting to install,

remove or perform maintenance work on batteries.
When on-charge float voltages must be measured, be
particularly careful because shorting a battery at this
time can cause not only personal injury, but severe
equipment failure as well.

Do not tamper with any parts of the battery, including

cover, vents, terminal covers, etc.

Keep batteries clean and dry. Use ½kg of baking soda

in 4litres of water to neutralise any possible acid. Do
not use cleaners or solvents on any part of the
battery. Do not allow excessive dust to accumulate on
the battery or cabling.

Keep battery connectors clean, greased and tight. A

loose connection can reduce battery standby time and
cause battery fires.

WARNING! Do not turn batteries upside down or tilt to
the front more than 30° as this will ‘wet’ the vent with
electrolyte which will be vented when the cell is
charged.

2.2 Sulphuric Acid
The VALEN 2V GEL Battery is a lead acid battery and
contains sulphuric acid in diluted form. Since the
electrolyte is immobilised, in the event of a container
rupture, no liquid acid will leak or run from the battery.

However, if the internal components of the battery are
touched or handled, contact with the acid will result.

CAUTION! Sulphuric acid can cause burns and serious
injury if it comes in contact with your skin or eyes. In the
event of contact with sulphuric acid, flush thoroughly
with water and neutralise any residual acid with baking
soda (1kg in 4litres of water). Seek medical attention
immediately. Do not handle batteries if the container
has been ruptured except while wearing rubber gloves.
Do no try to disassemble a cell.

2.3 Gassing
All lead acid batteries emit some gases during charging
and float operation. Conventional flooded batteries
release all the gases produced to the environment
whereas sealed, valve-regulated batteries recombine
most of the gases internally, releasing very little to the
environment. Compared to a flooded battery of equal
capacity, a VALEN 2V GEL Battery releases a gas volume
of 1% or less than the flooded battery. Due to this
characteristic, no special ventilation is required under
normal usage conditions. Since some gas is released from
lead acid batteries, never charge or use batteries in an
unventilated space.
This gas consists of mostly hydrogen gas and can explode
if ignited in a confined area or space. Keep sparks, flame
or any other ignition source (including smoking materials)
away from batteries.

CAUTION! Hydrogen gas can explode and cause serious
injuries and fire. Do not allow any flame or ignition
source near batteries. Always allow some ventilation
around operating batteries. Contact REGAL ELECTRO if
there are any questions regarding gassing or
ventilation.

2.4 Electrical Shocks
Batteries store large amounts of electrical energy. Even a
discharged battery can deliver a high short circuit
current. Keep all metallic objects away from the battery
terminals. Multi-cell systems can attain lethal voltages.
Remove all jewellery before working on batteries. Cover
all tools with vinyl electrical tape to minimise the
possibility of shorting a battery during installation. Never
lay tools or other metallic objects on batteries. Do not
allow construction work over batteries to proceed unless
the battery is protected by insulating rubber mats.

CAUTION! Shorting a battery can cause serious injury,
fire or explosion. Do not attempt to work on a battery
unless you are familiar with battery installation
procedures and have adequate safety information and

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equipment. Read this manual thoroughly before
attempting to install the battery. If there are any
questions about safety, contact REGAL ELECTRO before
installing the batteries. Remember, safety is always the
prime concern.

SECTION 3 - RECEIPT OF EQUIPMENT

3.1 Delivery Inspection
Immediately upon delivery, inspect the modules for
damage caused in transit. Damaged pallets could
indicate rough, improper handing in transit. Describe in
detail (take photographs) any damage of the delivery
receipt before signature. If any damage is found, contact
the carrier immediately, request an inspection and file a
damage claim.

3.2 Hidden Damage
Within 10 days of receipt, measure and record open

circuit voltages (OCV’s). If any damage is found, request

an inspection by the carrier and file a hidden damage
claim. Do not delay this step as it may result in a loss of
right of reimbursement for hidden damages.

SECTION 4 - STORAGE

4.1 General
Do not store batteries outside, exposed to the elements.
Store indoors in a cool, dry location. Do not store
batteries in temperatures over 30°C. The recommended
storage temperature is 20°C or less. Do not stack pallets
or possible battery damage may occur. Do not store
where the possibility of metallic objects falling on the
battery may occur.

4.2 Short Term Storage
VALEN 2V GEL Batteries are shipped fully charged from
the factory. If the batteries are to be stored 6 months or
less at 20-25°C or less before being put into service,
nothing need be done at this time. If the batteries are to
be stored longer than 6 months, at temperatures greater
than 25°C, or installation is delayed beyond expected
time, a storage charge may be required. A storage charge
is an equalising charge applied to a battery that is stored
in open circuit (not float charging) condition. See section

6.5 for details.
If the storage temperature is 20°C or less, VALEN 2V GEL
Batteries must be charged at least every 6 months while
in storage. For every8°C increase above 20°C, the storage
time between charges is cut in half. Therefore, at 28°C

the max. storage time is 2-4 months. At 24°C the max.
storage time would be 4-5 months.
Storage of batteries beyond the recommended
temperatures of storage times, without charging, can
result in loss of capacity, cell shorting and loss of float
life. It can also void the battery’s warranty. Keep careful
records of battery time of arrival, storage time and when
last charged.

SECTION 5 - GENERAL INSTALLATION PROCEDURES

CAUTION! Before attempting to install VALEN 2V GEL
Batteries, study this section and the section on safety
thoroughly. Failure to do so could result in personal
injury and battery or equipment damage.

5.1 Battery Location

5.1.1 Temperature
Battery location is very important in determining life and
performance of the battery. The ideal environment would
be a dry, indoors, temperature regulated area. The ideal
operational temperature is 20°C. Operation at
temperatures below this will result in a loss of battery
performance and may result in a larger, more costly
battery being needed. Operation at temperatures above
20°C will result in loss of battery operational life. For
every 8°C rise in battery temperature above 20°C, the life
expectancy of the battery will be cut in half. For example,
the VALEN 2V GEL Battery is designed for a 15 year float
service life at 20°C. If the battery were to be continuously
operated at 28°C, the life expectancy would be halved.

5.1.2 Temperature Variation

Maintaining temperature balance across the string is
very importance for max. battery life. The difference
between the maximum and minimum cell temperature in
a series string shall not be more than 3°C. Excessive
temperature variation will result in the need for
equalisation and may result in loss of battery operational
life.
Sources of battery temperature variation can be
placement of the battery system near a heat source such
as radiators, power equipment, windows or heating
vents. Air conditioning vents can also cause temperature
variations. It is recommended that the battery location be
designed, engineered and monitored to minimise
temperature variations.

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5.1.3 Ventilation
Proper ventilation of VALEN 2V GEL Batteries is important
for two reasons:

1. To minimise battery temperature variation and

2. To minimise build-up of potentially explosive hydrogen
gas.

5.1.3.1 Ventilation and Battery Temp. Variation
Recombinant batteries such as VALEN 2V GEL Batteries
give off a small amount of heat during charging and float
operations. Proper ventilation is important to remove this
heat and to prevent temperature differences from arising
in the string. Sufficient air circulation should be present to
prevent temperature layering effects. In an improperly
designed room, there can easily be a 5°C difference in
temperature between the floor and the ceiling. If this
difference exists in a series string, it will result in a need
for equalisation and in reduced battery life.

5.1.3.2 Ventilation and Gassing
As noted, lead acid batteries emit small amounts of gas
during normal charging and floating. The gas
composition, while on float, is approx. 80% by volume
hydrogen with the remainder being oxygen.

CAUTION! Hydrogen gas can be explosive. Never install
batteries in an air-tight space. Ventilation must be
provided to remove this hydrogen gas. Allow about 1
litre/hour/cell of air exchange to prevent hydrogen
accumulation.

NOTE! In virtually all cases, the amount of air circulation
required for battery cooling and temperature variation
maintenance will far exceed the amount of air
circulation required to prevent gas build-up. However,
ensure some air exchange is present in the ventilation.

5.1.4 Floor Loading
Before installing the modules, it should be ascertained
that the floor has the capability to support the weight of
the battery and related equipment. The total system
weight will be the sum of the modules plus 5% for the
battery connectors and other components. It is the
responsibility of the installer to ensure adequate floor
load carrying capabilities.

5.1.5 Seismic Considerations
VALEN 2V GEL Batteries are capable of withstanding
seismic events of UBC Zone 4 magnitude in horizontal
stacks of up to 9 modules high and when properly
installed. When seismic capability is desired, suitable
floor anchoring should be provided. Proper floor
anchoring is the responsibility of the installer. Ensure that

the anchors used are of sufficient strength to withstand
the max. seismic load foreseeable.

5.2 Unpacking
VALEN 2V GEL Batteries are shipped on pallets with
cells/modules in the horizontal position. All the
accessories needed for installation and use are packed in
boxes and shipped on top of the modules or on a
separate pallet. Unpack all items carefully and note the
quantities received.

5.3 Installation

5.3.1 General

NOTE! The lifting slings/straps provided are designed to
life one module at a time. Never attempt to lift more
than one module at a time or you will damage the
module.

VALEN 2V GEL module types are designed to be stacked
in the horizontal position. Modules are configured to
provide the termination at the top of the battery while
providing the shortest possible connections. When a
system requires fewer cells than are needed to
completely fill all modules, the extra spaces will be filled
with a dummy cell(s). Place the modules with the dummy
cells at the top of the stack.
VALEN 2V GEL batteries when mounted in the vertical
position may be placed end-to-end or side-by-side or a
combination of the two. Note that standard horizontal
configuration will be supplied unless specified differently
at time of order. Also note that when modules are
vertically mounted, they do not meet seismic zone 4
qualifications.

NOTE! Handle/lift modules by the lifting slings hooked
diagonally in front and rear mounting channels only. Do
not lift the battery/module by the cells because damage
to the cells will result.

5.3.2 Location Layout
Ensure that sufficient space is available for handling and
placement of the modules. Do not locate the battery
system near a source of heat or in direct sunlight. Locate
and mark the position of the battery system. Leave a
space of at least 900mm between the front of the battery
and any adjacent equipment.

5.3.3 Horizontal Module Installation
Hook the two lifting straps diagonally across the top
module on the pallet. Then, by removing 3 front bolts,
unbolt the module from the module below and lift one
module at a time from the pallet using a crane or fork

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truck. When all the modules have been lifted off the
pallet unbolt the base support from the wooden pallet.
Place the base support in position and drill the anchors
bolt holes down into the floor then remove the base plate
and increase the size of the bolt holes in the floor to suit
the size of the anchor bolts. Bolt down the base plate on
a level floor and check with a spirit level. On an uneven or
sloping floor it may be necessary to use shims. Bolt down
the base support and check the level again in both
directions.
Using the wiring diagram supplied, identify the bottom
module and lift with diagonal hooked straps/slings. Lift
the module with the crane or fork truck and gently lower
into place on top of the bolted down base plate. Locate
the three pins at the back of the module and push back
into place. Then bolt loosely from the front to the base
plate using the 3x M10 bolts supplied. Repeat the lifting
procedure with the next module and lower in place on
top of the bottom module. Engaging the three location
pins push back into place then bolt the second module to
the module below using the 3x M10 bolts provided.
Repeat this procedure until all the modules are in place.
Ensure that the module stack is plumb and level as the
modules are being assembled. Then torque the bolts to

11.4n.m. when the modules are fully assembled and
aligned.
Read section 5.4 then using the wiring diagram fit the bus
bars between the cells and the top terminal plates. When
connected check the battery voltage to ensure that the
cells are connected in the correct polarity. Then torque all
the terminal bolts to 11.4n.m. Fit the cell numbers
starting at the positive post with no.1. Check the cell
voltages and record with the cell ID. Fit the clear
insulating cell covers. The clear terminal plate covers
must be filled when the terminal cables are being
connected.
If the battery system consists of multiple stacks, the
stacks are positioned 12mm apart next to each other side
by side. The base plates are bolted together between
module stacks. The uppermost modules of the adjacent
stacks must be bolted back and front together using the
tie plates provided. The tie plates with captive nuts are
designed to fit in the module channels and be bolted
through the module mounting channel holes. The tie
plate modules is fitted then slid into the adjacent module
and bolted.

5.3.4 Vertical Module Installation
When modules are installed in the vertical position, the
modules are bolted to the base plate through the
bottom/back channel of the module. Attach the hooks in
the slings to the channels. Repeat this procedure with the

remaining modules. The modules must be bolted
together with 3 M10 bolts/module. When assembling
modules end to end bolt the modules together using the
tie plates supplied. It is always highly recommended to
attach the battery system to the floor using suitable floor
anchors. Note that modules installed in a vertical position
do not meet seismic zone 4 qualifications.

WARNING! Do not turn batteries upside down or tilt to
the front more than 30° as this will ‘wet’ the vent with
electrolyte which will be vented when the cell is
charged.

5.4 Electrical Connections
Proper battery electrical connections are very important
for the best battery performance and utility. Improper
battery connections can cause a loss of standby time or
even a battery fire. Follow the electrical connection
instructions carefully and review section 2.4 thoroughly
before working on the battery. Make sure that all
terminals and interconnects are cleaned and are covered
with the no-oxide grease provided.

CAUTION! Remove all jewellery before installing the
connectors on the batteries. Ensure that all tools are
insulated with vinyl electrical tape to prevent shorting.
Do not reach or lean across batteries. Remember
hazardous voltages may be present. Be aware of what
you are touching at all times. Do not hurry, take your
time.

5.4.1 Cabling Recommendations
Battery ratings are specified at the terminals of the
battery. The cabling used to connect the battery
terminals to the load has a voltage fop (when the battery
is discharging) that is dependent on cable length and
conductor size. The longer the cable run, the greater the
voltage drops.
The smaller the cable wire diameter, the greater the
voltage drop.
Therefore, to get the best performance from the battery
short, heavy cables are recommended. Do not size the
cables based on current carrying capacity only. A general
rule of thumb is to allow no more than a 20-30mV of
voltage drop/metre of cable run. As an example, if it is
10m from the battery to the load, the cable should be
sized to allow no more than 2 x 10 x .030 = 0.6V drop.
In order to help select cable sizes for load connections,
the following should be consulted:

Cable Properties at 20°C

Cable Area Size

mm²

Max. Amps

30mV Drop/m

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8AWG

8.4

15 6 13.3

23 4 21.2

37 2 33.6

59 1 42.4

74 0 53.5

93

00

67.4

117

000

85.0

148

0000

107.2

187

250MCM

126.7

221

350MCM

177.4

309

400MCM

202.4

353

Use 1.74A/mm² for other cable sizes.

5.4.2 Terminal Preparation
Gently clean the contact surface of the terminals with a
brass bristle brush or a Scotch Bright pad. Immediately
after this cleaning, apply a thin layer of No-Ox-Id ‘A’ or
NCP-2 antioxidant grease to the contact areas. A
petroleum jelly such as ‘Vaseline’ may also be used.

5.4.3 Connector Installation
The VALEN 2V GEL Batteries are supplied with intercell
busbars or cables sized for the specified discharge time.
The busbars are plated with a tin-lead alloy and should
require little or no cleaning prior to installation. If the tin­plated busbars need to be cleaned, carefully use a Scotch
Bright pad or a soft brass bristle brush to clean. Take care
to ensure the plating is not removed. Lightly grease the
contact surfaces of the busbars before installation.
Following the supplied wiring diagram, install the
intermodule/interstack connections carefully using the
supplied M8 and M10 bolts and washers supplied and
tighten the hardware finger tight.

CAUTION! Use extreme care not to short the battery
connections. VALEN 2V GEL Batteries are capable of
very high short circuit currents containing a very high
energy level.

Before the final tightening of the intercell connections,
visually check that the connections are properly made
and in the proper sequence. See section 5.5.4 for the
proper procedure for checking string voltage. When
proper connection has been verified, torque all intercell
connections to 11.4n.m. including the factory-made
connections.
Install the terminal plates by attaching the plastic strip to
the front of the top module channel using the supplied
hardware. Attach the terminal plates to the cell terminals
and to the plastic support. Torque hardware to 11.4.n.m.
When installing the battery load cabling, attach the load
cabling to the wall or the cable tray so that the weight of

the cable is not on the battery terminal plate. If using a
stiff cable, pre-bend the cable so no ‘spring’ force is
placed on the terminal plate. Failure to support the cable
weight could result in premature cell failure and loss of
battery integrity. Fit the terminal plate insulating cover
over the cable before bolting to the terminal plate.

5.4.4 Voltage Checks
Visually check that all connections are properly made
(positive to negative) and are tight. Measure string
voltage, check that this is about 2.14 x No. of cells.

CAUTION! High Voltage may be present.

The total string voltage should be approx. 2.13-2.15V
multiplied by the number of cells in the string (for 24 cell
battery 51.12-51.6V). If the measured string voltage is
not close to the calculated value, recheck the battery
connections to ensure proper polarity sequence and
measure the individual cell voltages. Calculate the
average cell voltage and use this value to recalculate the
string voltage. If the recalculated and measured string
voltages do not match reasonably well, contact REGAL
ELECTRO for further instructions.

5.4.5 Battery to Charger Connection
Ensure that the charger is disconnected from the power
line. If a battery disconnect is installed, open it.

NOTE! The positive terminal of the battery bank should
be connected to the positive terminal of the charger and
the negative terminal of the battery bank should be
connected to the negative terminal of the charger.

5.4.6 Paralleling of Batteries
When greater capacity is desired than available from a
single cell or string, paralleling of batteries becomes
necessary. Batteries must be properly paralleled in order
to get the best system performance and longest battery
life.
The battery strings must be treated as equally as
possible. This means equal length cabling to a common
collection point for the load cables, uniform temperature
between the strings and equal strings of batteries. Do not
parallel flooded batteries with valve-regulated batteries if
the charge voltages differ between the batteries. Ask
REGAL ELECTRO for advice on paralleling flooded and VR
batteries.
To check the proper paralleling of the strings, connect the
strings in the final form and place a load on the battery.
Measure the load cable voltage drops. The voltage drops
should match within 10%.

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SECTION 6 - OPERATION

6.1 Initial Charge
The initial charge on the battery is essentially an
equalisation charge of the battery. Always perform this
charge of the battery when it is first installed. Failure to
do so could result in uneven float voltages and low initial
capacity.
The equalisation or initial charge voltage in this case, for
the VALEN 2V GEL Battery is 2.35V/cell at 20-25°C.
Calculate the initial charge voltage for your installation,
based on the number of cells in the string. Turn on the
charger and raise the charger output voltage (using the
equalisation control) to the calculated value (for 24 cell
battery this is 56.4V). Leave the string charging at this
level for 12 hours to a maximum of 24hours. (Check after
3 hours that the string voltage has not changed). At the
end of this time, reduce the charger output voltage to the
float voltage (2.25V/cell at 20-25°C).
See section 6.2 just prior to reducing the string voltage to
the float voltage, measure and record the individual cell
voltages and cell ID’s.
If the charger output voltage cannot be raised to the
calculated initial charge voltage or the load cannot
tolerate a charge voltage this high, raise the charger
output voltage to the maximum permissible level.
Measure the charger output voltage and calculate the
voltage/cell. Use the following as a guide:

Max. Voltage Obtained

(25°C)

Charge Time (Hrs)

Min/Max.

2.32-2.33vpc

24/12

2.29-2.31vpc

48/36

At voltages below 2.29vpc, adequate equalisation will not
be obtained. Contact REGAL ELECTRO for additional
procedures to equalise a battery under these conditions.

If the ambient temperature is not in the range of 20-25°C,
the initial charge voltage will have to be temperature
compensated. TC = temperature compensation is the
process whereby the charge voltage is changed as the
function of the battery temperature. The temperature
correction factor (TCF) for VALEN 2V GEL Batteries is -

0.003V/Cell/°C from a 20°C baseline temperature. This
means that as the battery temperature rises (falls) above
(beneath) 20°C, the charge voltage must be reduced
(raised) the TCF amount for every degree of change. The
formula to calculate the temperature corrected voltage

is:
TCV = chg. Voltage (20°C) - [T-20°C] x (-0.003v/c)
As an example, if the initial charge was going to be
performed at 28°C the temperature corrected charge
voltage would be:
TCV = 2.35 - (28-20) x (-0.003v/c) = 2.31v/c

6.2 Float Voltage
The float voltage is sometimes known as the continuous
charge voltage. It is very important that it be calculated
and set properly for max. battery life and performance.
The purpose of the float voltage is to provide enough
float voltage and current to the battery to compensate
for self-discharge and maintain the battery in a fully
charged condition of readiness.

FAILURE to properly follow float voltage
recommendations can result in loss of warranty and
premature battery failure.

6.2.1 Float Voltage Requirement
The allowable float voltage range for VALEN 2V GEL
Batteries is 2.27-2.23v/c at 20-25°C. The recommended
float voltage setting is 2.23-2.25v/c at 25°C or 2.25-

2.27v/c at 20°C. The average recommended setting being

2.25v/c.

6.2.2 Float Voltage Temperature Compensation
The float voltage temperature compensation factor is -

0.003v/c/°C from a 20-25°C baseline (the same as the
equalisation TCF). For temperatures, around 25°C, use
the following table:

Temperature

°C

Float Charge

v/c

10

2.300

15

2.275

20

2.250

25

2.225

30

2.200

35

2.175

For temperatures, outside of this range see section 6.1 for
the equation used for calculation of the temperature
corrected float voltage.

6.3 Maximum Charge Current
The maximum charge current is limited to prevent the
possibility of charging the batteries at a higher rate than
they can efficiently accept. Greater than recommended
maximum charge currents can result in excessive battery
heating and gassing and a shortened battery life. The
maximum normal charge current is the C5 rate in Amps.
If a very rapid recharge is desired, please contact REGAL
ELECTRO for more instructions.

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6.4 Recharge
Recharge batteries immediately or as soon as possible
after a discharge. Do not wait more than 24hours to
initiate the recharge after the batteries have been
discharged. Failure to do follow this recommendation
could result in a permanent loss of capacity due to plate
sulphation.
The approx. recharge time can be calculated as follows:

Ah Discharged

Avail. Charge Current

Where F = 3 if the batteries are charged at the float
voltage and F = 2 if an equalisation voltage is needed.

6.5 Equalisation Charge
The equalisation charge voltage of the VALEN 2V GEL
Battery is 2.35V/cell at 25°C. While equalisation is not
required by the VALEN 2V GEL Battery under normal
operating conditions, it is possible to operate the battery
in such a way that equalisation would be needed. These
conditions would include:

Temperature variation in the string greater than 3°C
Low float voltage
Low operational temperature without temperature

compensation

Frequent deep discharges
Rapid recharge required
Long delay in recharging the battery after a discharge
Unevenly paralleled string balance

Equalisation should be performed on an ‘as needed’

basis. The standard equalisation would be 12-24hours
maximum at a constant voltage of 2.35VPC at 20°C to
25°C. For equalisation at voltages and temperatures
other than the above, see section 6.1 for methods to
compensate.

SECTION 7 - STORAGE

When installed VALEN 2V GEL Batteries will not be used
(floated) for a period of time, the following procedure
should be followed:

1. Equalise charge the battery (refer to section 6.5)

2. Disconnect the battery from all loads. Do not allow any
loads, no matter how small, to remain connected.

3. Equalise charge the battery every 6 months when the
storage temperature is 20°C to 25°C or less. For every 8°C
rise in storage temperature, reduce the equalisation
interval by half.

4. Perform an equalisation charge on the battery prior to
returning to service. During the storage time, particularly

if it is extended, it is recommended to continue to
monitor and record battery voltage levels. Measure and

record the battery open circuit voltage and cell ID’s just

before equalisation and then record the on-charge
voltage and current just prior to completing the charge.
Refer to section 4.0 for more information.

SECTION 8 - MAINTENANCE AND RECORD KEEPING

Maintenance and record keeping is critical to battery life
and warranty continuance. Proper maintenance will
ensure that the batteries are being correctly used and will
be available when needed. Proper record keeping will
ensure that, if there is a problem with a battery, the
customer can demonstrate the batteries were correctly
used and so maintain the warranty.

8.1 General Maintenance
General maintenance of the battery means keeping the
battery and surrounding area clean and dry. Since VALEN
2V GEL Batteries are of low maintenance design, there is
no addition of water or specific gravity checks needed for
the life of the battery. The only required maintenance
action is an annual retorque of the battery connections to
100in-lbs. (11.4N-m). Review section 2.4 on Electrical
Shock before performing this action.

CAUTION Always use insulated tools.

Do not use any solvents or strong cleaners on or around
the batteries. A dry brush may be used to remove any
dust accumulations. If required, a solution of 1kg of
baking soda in 4L of water may be used as a
multipurpose cleaner if more stubborn stains or dirt
accumulations are present.

8.2 General Records

8.2.1 Installation Records
When the battery is received, record such things as:

Date of receipt
Condition of the modules
Open circuit voltages (if measured)
Date of installation
Original PO number
Installer(s)
Equalisation time and voltage
Any unusual storage conditions

8.2.2 Maintenance Records
At least twice per year, record the following:

Cell float voltage

x F = no. of hours to charge

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String voltage
Float current
Ambient temperature
Battery temperature
Battery conditions
Any unusual charges or discharges - 6months

Keep the above records in a safe place for review by
maintenance personnel. Remember, these records are
mandatory for any warranty claim on the battery.

SECTION 9 - CAPACITY TESTING

9.1 General
Discharge testing of the battery is performed to
determine the battery capacity. There are two reasons
for performing this test:

1. A ratings test discharge - the intention here is to
determine the percent of battery capacity as compared to
the rated capacity. This is typically a 3, 5, 8 or 10hour
discharge test.

2. A service test discharge - this test is to determine the
battery standby time under the actual load conditions of
intended battery usage.
The ratings test discharge is usually performed using a
suitably designed and sized load bank to provide a
constant current load to the battery. The test is
performed for the specified period of time to an end­point voltage per cell (usually 1.75 to 1.80VPC) with the
Ah capacity of the battery calculated by multiplying the
load current by the number of hours of run time. The
actual Ah capacity can be compared to the rated Ah
capacity to determine percentage capacity. This type of
test is usually used as an acceptance test of the battery.
The service test is usually performed by placing the actual
load on the battery and determining the actual time the
battery will support the load. This test is done, in the case
of a UPS, by switching into a test mode where the battery
becomes the primary power source and the normal AC
line becomes the back-up. If the load is not critical, the AC
input can simply be shut off to simulate a loss of power
event and total system operation can be verified as well.
A load bank can be used if the normal battery load is well
defined.

9.2 Test Procedure
The battery test procedure for either test is:

1. Ensure the battery is fully charged before capacity
testing and that all connections are clean and torques
tight. An equalisation charge is highly recommended

before performing a capacity test and is mandatory if the

battery is new or has not been on continuous float for at
least one week or if there is any questions about the

battery’s state of charge.

2. Prepare the load bank or test load system. Ensure all
temporary cable connections are secure and connected to
the proper polarity, and have sufficient current carrying
capacity.

3. Determine the battery temperature by measuring and
recording the temperature of every 6 cells. Average the
readings to determine the average battery temperature.
Measure the cell temperature in the middle of the
module (preferably) or the end wall of the module.

4. If a ratings test is being performed, the load current or
power must be temperature corrected if the battery
temperature is significantly different from 20°C to 25°C.
The formula for calculating corrected load is:
Temperature corrected load = load at 20°C to 25°C x CF,
where CF is the capacity correction factor for
temperature. The following table should be used:

Test Temperature °C

Capacity Correction

Factor (CF)

0

5
10
15
20
25
30
35

0.84

0.89

0.94

0.97

1.00

1.02

1.04

1.05

If the service test is being performed, no temperature
correction is necessary.

5. Just prior to starting the discharge test, measure and
record the individual cell voltages, the string voltage and
float current. This can be accurately measured using a
calibrated shunt.

6. Remove or disconnect the charger from the battery
string.

7. Connect the load to the battery and start a timer.
Monitor the string voltage and record the lowest voltage
reached and the time reached.

8. Record the load current, string and individual cell
voltages on a regular basis. A minimum of three sets of
readings should be taken. The time interval between sets
of readings will vary based on the expected test time. For
example, take readings every hour for the first 4hours of
an 8hour rating test. For the following 3hours take
readings every ½hour. For the last hour, take readings
every 15minutes. For a 15minute UPS discharge, a
reading every 5minutes is desirable.

9. Continue the discharge until the string voltage drops

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below the end-point voltage per cell times the number of
cells in the string.
For example: 1.75VPC x 24cells = 42.00V is the stop
discharge voltage. Do not be concerned if the voltage of
some cells falls below 1.75 on a new battery, these cells
will be restored to full capacity when the battery is
recharged.

10. Stop the timer and remove the load from the battery.

11. Immediately recharge the battery using the existing
charger or an external charger. An equalise voltage may
be used to reduce charge time.

12. Record the discharge time and calculate percentage
capacity if a ratings test was performed.

13. Keep a copy of all the test data with the battery
records.

DISCHARGE TEST NOTES:

1. When the batteries are new, the battery may deliver
only 95% of rated capacity. Full capacity will be obtained
after 3-6months in float service or after cycling about 10
times.

2. String voltage should be measured at the battery
terminals, not at the load connections.

3. Accurate meters are essential for correct test results.
Ensure all meters, shunts, etc. are properly calibrated
before use.

4. If a long duration test is being performed, the terminal
to terminal voltage drop across the intercell connections
should be measured and recorded. This will serve as a
reference for any needed terminal maintenance work and
will assist in verifying the battery integrity.

5. A float voltage check after the test and recharge is
desirable, but not required information.

STANDARDS

All system specifying and installation should be in
accordance with Australian Standards:

AS4086.1-1993 Secondary batteries for use with

stand-alone power systems – General requirements

IEEE1375:1998 (R2003) Protection of Stationary

Battery Systems

IEEE485:2010 Recommended Practice for Sizing Lead-

Acid Batteries for Stationary Applications

AS/NZS4509.1:2009 Stand-alone power systems –

Safety and installation

AS/NZS4509.2:2010 Stand-alone power systems –

System design

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SECTION 10 – BATTERY REPORT

VALEN GEL 2V BATTERY REPORT

Installed by:

Representative:

Operating Company:

Date:

Time:

Battery Information

Type of Battery:

No. of Cells/String:

String Float Voltage:

Installation Date:

No. of Strings/Battery:

Battery Charge Current:

Battery Code:

Float Current:

Charging Equipment:

Ambient Temp.:

Bloc Temp.:

Battery Charger Information

Make:

Type:

Current Rating:

Model:

Year of Manufacture:

Charging Voltage:

INDIVIDUAL CELL READINGS

Cell
No.

Cell
ID

Float
Volts

Cell
No.

Cell
ID

Float
Volts

Cell
No.

Cell
ID

Float
Volts

Cell
No.

Cell
ID

Float
Volts

Cell
No.

Cell
ID

Float
Volts 1 26

51

76

101 2 27

52

77

102 3 28

53

78

103 4 29

54

79

104 5 30

55

80

105 6 31

56

81

106 7 32

57

82

107 8 33

58

83

108 9 34

59

84

109

10

35

60

85

110

11

36

61

86

111

12

37

62

87

112

13

38

63

88

113

14

39

64

89

114

15

40

65

90

115

16

41

66

91

116

17

42

67

92

117

18

43

68

93

118

19

44

69

94

119

20

45

70

95

120

21

46

71

96

121

22

47

72

97

122

23

48

73

98

123

24

49

74

99

124

25

50

75

100

125

Remarks and Recommendations:

Signed:

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VALEN GEL 2V BATTERY MAINTENANCE REGISTER

Date

Maintenance Description