Things you need to know about batteries

Batteries are built with a specific purpose in mind. This encompasses the materials used in the manufacture of the battery, the glues/adhesives used. The types of plastics used in the case and many other physical attributes. But there are things that can't be seen or measured easily like, the thickness of plates, Specific Gravity (SG) of the acid which has a huge impact on the battery's ability to give a high CCA when new, but if a high SG also limits the batteries longevity.

The next is true of all batteries and brands but we'll generalise one brands product offerings to give an overview of how their models within the range differ. And we'll be even more specific and limit this article to just AGM batteries within a single brand to give a better overview of the variations.

The first and cheapest entry-level AGM would be a 3-5 year design life battery (which means typically a 1 year warranty) it also means traditionally a battery manufactured with cheap labour and high volumes of turn over. Design life does not mean it will last 3-5 years either, the product will typically last 2-3 years in its desired application. Please note if you use it in the wrong application it might only last 6 months to a year. These batteries are also always referred to as float life batteries as they are meant to be connected to a charger or power supply full time like used in an alarm or UPS system.

Next would be a float life battery with a 10-year design (meaning it might last up to approx 8 years if conditions are suitable). These are occasionally used as an entry point deep cycle battery as they will give approx 250 cycles to 80% which would be similar to use of an occasional user in a cyclic application like a weekend motorhome or boat enthusiast. They might advertise 400-500 cycles at 50% but this can rarely be proven.

Then you'd enter step up to the next design of thicker plated batteries with a lower SG level to give the batteries a better reserve performance over a longer duration. This is really where true deep cycle batteries start. They might have an advertised performance of 800-1200 cycles at 50% depth of discharge. They are also flat plate construction and in a general statement we'd say are the high end of Chinese production. These batteries will however all look the same as the above 5 and 10 year design float life batteries so you really need to know what to look for and test yourself to prove the claims of capacity and longevity.

If you were to try comparing one brand with another you must first match the above 3 characteristics before reviewing and matching apples with apples the following technical specs: Amp hour, C rate (number of hours discharged to calculate the Amp hour rate), end voltage of discharge rate, temperature of discharge rate, start temp of discharge rate test, weight of the battery. Again, like for like as in AGM with AGM, not AGM with Lithium or AGM with Lead Carbon). Cycle life vs. depth of discharge. Once you have worked your way through that nightmare, brand, warranty or number of pages and exclusions, after sale service, advice given up front vs. retrospective, cost, location, distribution, ability to diagnose or test if there is ever an issue. All these need to be reflected to get a sense of value or worth in a battery.

That typically brings us to the end of the upgrade path by a single brand as the technology doesn't change for a 6 volt or 2 volt cell if its AGM. There are other chemistries available from the same said manufacturer like OPzV which are typically a tubular gel and in many cases far superior to the 12 volt AGM deep cycle batteries with cycle life charts normally starting at 1000+ for 80% Depth of Discharge. Do not even confuse these with traction batteries, they are used very differently from a reserve capacity battery.

As far as OPzV or traction batteries are concerned do not think they are better for you though, it's all about the balance of charge time, current and discharge rate. Mostly there is a cost difference and which point you might consider Lithium. This is where expert advice is required to match your use with the intended purpose of the battery and your available charging systems.

Returning to traditional 12 volt batteries or the slightly higher capacity 6 volt cells we then move to high-end global brands where the reputation of the brand is world-renowned. Like Odyssey, SunXtender, Lifeline, Optima, Trojan, Sonnenschein. These batteries typically use industry-standard systems for measuring performance, life cycle and are well proven and offered by distributors like ourselves because of the brand's reputation and the requirement to service and support with adequate ability.

5 things you need to know about importance of correct sizing and purpose

  1. When you select a battery charger you need to first choose a style or form that is appropriate for the task at hand. A desktop charger isn't suitable in an application where the charger needs to be retained or mounted. These form factors may include dust or water ingress considerations or power cables in and out of the unit.

  2. When selecting a battery the capacity required for you to run with a few day's autonomy needs to be matched with a batteries need to be recharged with the appropriate sized current. As a general rule we say use 1/10th batteries AH for its charging rate given you have 12 hours to recharge overnight. If you have less time then you need a larger charger if the battery can accept a higher rate of charge. Or if you are using some of the charging power to run equipment while the charging is simultaneously occurring.

  3. The intended use of the battery is a key factor in the life you will get from it if you use a starting battery in a deep cycle application then be prepared for an early end of life. If you have recently increased your Ah capacity because you required a longer autonomy and used a deep cycle battery but have not increased your charging current to match you can also expect issues. Using any battery charger or regulator which doesn't use the factory recommended recharge voltages of the battery you are charging will lead to an early end of life issues also. These are not covered by the manufacturer's warranty which covers physical defects in production.

  4. Chargers are a logic programmed electrical device that uses timers and measurements of voltage and current to determine the charge cycle. They are therefore pre-programmed with time limits for each stage, or current (amps) and a minimum value before the stage is complete then moving to the next stage of a charging cycle. If you haven't sized your charger correctly to your batteries these rates can be either too long because of undercurrent causing issues with recharge. Or just as annoying if the charger is too big you can reach high voltages quickly but not be able to change modes for a minimum number of hours which can lead to unnecessary overcharging.

  5. Purpose of the system design, simplicity, effectiveness, and efficiency are all core factors in power storage and conversion. Choosing the correct components from the outset might cost a little more upfront but the return well worth the effort in getting it right.

Direct DC Coupling

Morningstar has released a 600V MPPT Solar Controller that allows for direct battery charging in DC rather than going via the  inverter charge controller in a typical grid-tie solution. The intent is to eliminate the double conversion from solar panels being DC power through the inverter to mains then back through a charge controller into the batteries.

This isn't really something new its more of a variable option, it allows you to use your house's power via your distribution power board in the event of the grid going down.

Many people won't know that when the power provider or mains power line is not working if power is cut, that stops your solar panel system from functioning. If power is purposely disconnected because of rolling blackouts or accidental line failure or like in California U.S.A power has been cut to prevent fires from failures in the national grid in dry summer environments.

The Direct DC Coupling allows you to be more efficient and charge your storage batteries directly and keep your grid-tie system live. Other manufacturers call this an "island", an island is where you can operate independantly of the grid and distribute and manage your own resources.