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MTEKPRO Technologies Pvt. Ltd, New Delhi.

 Voltage

Measurement Impedance Measurement Sulfation Measurement Dryout

Physical

Inspection

MTEKPRO Technologies Pvt. Ltd, New Delhi.

Our Technology
CEL Scan (Chemical Electrical Layer Scanning) This Technology Brief reviews the basis and capabilities of CEL Scan (Chemical Electrical Layer Scanning) technology for assessing the health of lead acid and other batteries. CECRI ( Central Electrochemical Research Institute), Karaikudi is successfully using this instrument from last two years.

MTEKPRO Technologies Pvt. Ltd, New Delhi.

As implied by the name, Chemical Electrical Layer Scanning (CELScan) technology provides the capability of monitoring changes in both electrical and chemical characteristics of lead acid batteries. This capability permits the identification of incipient sulfation and/or dryout processes even when single-point measurements (e.g., conductance or resistance) register no appreciable deviation from nominal values.

MTEKPRO Technologies Pvt. Ltd, New Delhi.

MTEKPRO Technologies Pvt. Ltd, New Delhi.

Voltage Measurement
We will Check voltage using EC2000. Readings for
a charged, should be 12.8v (if per plate battery is 2.12 volts) or higher after the battery is charged and sits for at least 1 - 2 hours. If less, it needs an additional charge.

MTEKPRO Technologies Pvt. Ltd, New Delhi.

MTEKPRO Technologies Pvt. Ltd, New Delhi.

MTEKPRO Technologies Pvt. Ltd, New Delhi.

Even a partial discharge will cause sulfation on the plates that reduces battery capacity and leads to premature battery failure.
Do not leave batteries discharged! Damage can occur in a very short period.

MTEKPRO Technologies Pvt. Ltd, New Delhi.

Impedance Measurement
Impedance measurements can be performed by passing a current of known frequency and amplitude through the battery and measuring the resultant ac voltage drop across each cell/unit.

MTEKPRO Technologies Pvt. Ltd, New Delhi.

High impedance is another term for "high internal resistance". This means with age or poor maintenance, a rechargeable battery develops a high internal resistance causing the battery to collapse with heavy current demands. So, while the battery may show a 'full charge' on a volt meter and an acceptable capacity level on an analyzer, when put to the test the battery is not able to sustain the current draw for the application causing a low battery indicator. Lower the Impedance, Lower the chance of BLACKOUT!
MTEKPRO Technologies Pvt. Ltd, New Delhi.

The lead sulfate that forms on each plate of a lead-acid battery during discharge starts out as microscopic crystals that are easily converted back to active material during recharge. Over time, however, the smallest crystals tend to shrink and larger ones tend to grow. Left untended, the lead sulfate crystals eventually become so large that no amount of DC charging (even at elevated voltage) can reverse the process. At that point, the battery will not accept charge and is said to be sulfated.

MTEKPRO Technologies Pvt. Ltd, New Delhi.

Experience shows that sulfation can develop on the plates of a lead acid battery when it is:

Left for more than a few hours at a low state of charge state; Allowed to self-discharge for long periods after charging; Consistently undercharged; Operated at elevated temperatures; Consistently overcharged; Subjected to excessive AC ripple;

MTEKPRO Technologies Pvt. Ltd, New Delhi.

The lead sulfate that forms on each plate of a lead-acid battery during discharge starts out as microscopic crystals that are easily converted back to active material during recharge. However, left untended, the lead sulfate crystals can grow, eventually becoming so large that no amount of DC charging (even at elevated voltage) can reverse the process. The battery will no longer accept charge and is said to be sulfated.

Applying a patented, 3-Stage charging regime,

Dynapulse technology overcomes the problem of sulfation quickly, economically and safely.

MTEKPRO Technologies Pvt. Ltd, New Delhi.

Once sulfation has begun, the process tends to progressively worsen any irregularities in the distribution of charging and discharging currents within the plates. Furthermore, sulfation of just one cell in a string can degrade the performance, capacity, and ultimately the life of every other cell in the string. The degradation occurs because the increased resistance and reduced capacity of a sulfated cell leads to uneven states of charge among the other cells, promoting sulfation in undercharged cells and multiple failure modes in overcharged cells.

So when you know Sulfation level of your battery , It is easier to judge the battery condition.

MTEKPRO Technologies Pvt. Ltd, New Delhi.

MTEKPRO Technologies Pvt. Ltd, New Delhi.

While detailed aspects of Dynapulse battery conditioning technology remain proprietary, they involve the patented 3-stage regime outlined in Table . Current and voltage values given in the table are typical for a 12 Volt,~100Ah lead-acid battery. For other battery ratings, the values would be scaled appropriately.
Table 1. Three-stage desulfation regime

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An important failure mode observed in valve regulated lead acid (VRLA) batteries, is "dryout" - the progressive loss of water from the electrolyte.

MTEKPRO Technologies Pvt. Ltd, New Delhi.

When properly managed, VRLA batteries retain adequate water throughout their design lives. However, when subjected to prolonged overcharging, overheating, or when a valve malfunctions, water loss from VRLA cells can appreciably lower the separator conductivity. Dryout of an AGM (Absorbed Glass Mat) separator causes it to shrink away from the electrodes, ultimately producing a large increase in internal resistance and a sudden loss in capacity. Similarly, water loss from a gel separator can lead to disintegration of the separator and a corresponding drop in capacity.

MTEKPRO Technologies Pvt. Ltd, New Delhi.

Exacerbating the problem of dryout is a feedback effect whereby each increment of water loss increases both ohmic heating and (during charge) the oxygen recycle current. The increased heat generation further accelerates water loss, ultimately leading to a catastrophic failure process known as thermal runaway.
Hence, early detection of this failure mode will not only extend battery life, it may also avert a major accident.
MTEKPRO Technologies Pvt. Ltd, New Delhi.

Physical Inspection That means:

Check electrolyte level. Keep the top free of grime. Check cables, clamps and case for obvious damage or loose connections. Clean terminals and connectors as necessary. Make sure exhaust tube is free of kinks or clogs. Replace caps, finger tighten only.
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Deep discharge or prolonged discharge leads to harmful sulfation. A discharged battery freezes much faster than a charged battery. Charging can reverse discharging. Charging gives off hydrogen and oxygen, which are explosive.

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NOT NECESSARILY! A borderline battery may start the engine, but fail shortly after.

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For Further clarification please contact MTEKPRO Technologies Pvt. Ltd, New Delhi. www.mtekpro.com

MTEKPRO Technologies Pvt. Ltd, New Delhi.