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Battery Guide

POWER-SONIC BATTERY GUIDE 3*please contact us for further information

Our product range includes:

■ Valve Regulated Lead Acid (VRLA) batteries

also called Sealed Lead Acid (SLA) batteries

■ Nickel-Cadmium (Ni-Cd) cells and

battery packs

■ Nickel Metal Hydride (Ni-MH) cells and

battery packs

■ Alkaline cells and battery packs

■ Custom battery packs

■ Battery Chargers

Power-Sonic products are used

by many industries world-wide,

including:

■ Fire & Security

■ UPS / Standby Power

■ Emergency Lighting

■ Renewable Energy

■ Mobility

■ General Electronics

Power-Sonic Group was established in 1970 and has developed into a leading global supplier of VRLA rechargeable batteries offering excellent value at competitive prices.

Our corporate focus is dedicated to designing, manufacturing and selling the Power-Sonic brand of VRLA batteries, which we believe is amongst the most popular brand in the industry.

Our longstanding ISO9001 certificate endorses our

commitment to quality and improvement.

Power-Sonic’s in-house dedicated and experienced

service team ensures our customers are fully

supported from the time of enquiry through to

delivery and beyond.

■ Customised service solutions

■ Next day delivery in mainland UK

■ 3 - 5 day delivery throughout Europe

■ Advanced technical support

■ Scrap collection and recycling service*

Power-Sonic Battery Guide

Contents Page

Cell / Battery Description 5VRLA versus Flooded (Open Vented) Technologies 6Battery Design Life 7Self Discharge / Overcharge 8Undercharging / Temperature effect 8-9Application Guide 9Basic Lead Acid Chemistry 10Series / Parallel Connection 11Basic Battery Sizing 12Terminal Details 13Battery Construction 14Example of Applications / Non SLA Battery Types 15Battery Do’s and Don’ts 16Glossary 17Battery Safety / European Directives WEEE 2002/96/EC and RoHS 2002/95/EC 18The Battery and Accumulators (placing on the market) Regulations 2008 19The European Directive 2006/66/EC on batteries, accumulators and waste batteries 20R.E.A.C.H. (Registration, Evaluation, Authorisation and restriction of Chemicals) 20 Summary TablesPS Series, VO Series 22-23PG Series 24-25PSGL Series 26-27PSX Series 28OPzV Series 29Non SLA Series 30-31

POWER-SONIC BATTERY GUIDE 5

keeping you in chargeCell – A Cell is the simplest operating unit in a

battery. It consists of one or more positive plates, an

electrolyte, one or more negative plates, separators

between plates of opposite polarity, and a container.

The nominal voltage of a lead acid cell is 2v.

Commonly, the term battery also applies to a

single cell if it constitutes the entire electrochemical

storage system.

Cell / Battery Description

Typical 12v Battery (6 cells internally connected in series)

Battery – Two or more cells enclosed in a

container and electrically interconnected in an

appropriate series/parallel arrangement to provide

the required operating voltage and capacity.

Lead Acid batteries are composed of the following

sub-technologies, according to the battery design and

the manufacturing process:

■ Flooded type (open/vented)

■ Sealed Lead Acid type, however the more

accurate term is Valve Regulated Lead Acid

normally abbreviated to VRLA.

The main physical difference between the two

technologies is that the flooded type has free flowing

electrolyte whereas the electrolyte is immobilised in

the VRLA type.

Example of a VRLA cell

POWER-SONIC BATTERY GUIDE 76 POWER-SONIC BATTERY GUIDE

Design Life Float Service

The definition of design life is the service life time, in years, before the battery capacity falls below 80%

of its initial rated capacity.

Eg. For a 100ah battery, the end of life is reached once the capacity of the battery is reduced to 80ah.

Temp Effect On Battery Life

Heat has a dramatic effect on

battery life and as a general rule

of thumb, the life of the battery

is reduced by 50% for every

10° rise in temp from a base

temp of 20°C.

Cyclic Service

In cyclic applications the battery will reach end-of-life after a defined number of cycles. This number is dependant

upon the depth of discharge of each cycle. The deeper the discharge, the less number of cycles to end-of-life

conversely the lower the depth of discharge the more cycles to end of life.

The depth of discharge is expressed as the percentage of the battery capacity required per duty cycle.

Some Factors Affecting Battery Life

1 Design (variations from one

manufacturer to another)

2 Quality of materials (impurities /

imperfections)

3 Production methods

4 Quality control

5 Cycling profile

6 Environmental operating

conditions

7 Charging Regime

Temperature °C

% D

esi

gn L

ife

100%

75%

33%

7%

3%

20 30 40 50 60

Temperature Vs Life

Flooded Technology■ Uses high Antimony, low Antimony or Calcium Lead alloys or a combination of Calcium and low

Antimony (hybrid) Lead alloys

■ Requires maintenance

■ Its entire electrolyte volume is free to move within the cell with nothing to prevent the escape of

hydrogen and oxygen gases normally lost during charging

■ Is spillable, and therefore can only be operated in an upright position

■ Normally requires a separate battery room

■ Older Technology

VRLA Technology■ Cells are sealed using special pressure release valves and should never be opened

■ Typically uses Calcium/Lead alloys

■ Low maintenance – “Maintenance Free”

■ Uses a recombination chemical reaction to prevent the escape of hydrogen and oxygen gases normally

lost in a flooded lead-acid battery (par ticularly in deep cycle applications)

■ Is non-spillable, and therefore can be operated in vir tually any position

■ Safe

VRLA batteries can be categorised further and there are basically two types:

■ Batteries with the electrolyte immobilised in a special glass mat separator are commonly known as VRLA

AGM (absorbent glass mat) batteries

■ Batteries in which the electrolyte is immobilised by a Gel is commonly known as VRLA Gel batteries

There are two main features of a VRLA battery

One, it is sealed and uses special rubber valves to release pressure under abnormal overcharge conditions.

Two, it uses a chemical recombination system to prevent the escape of internal gases.

Operational Positions May be used in any operational position except for the inver ted position.


Temperature Effects On Capacity

Actual capacity is a function of

ambient temperature and rate of

discharge. At 20°C (68°F) rated

capacity is 100%. The capacity

increases slowly above this

temperature and decreases as

the temperature falls. At any

ambient temperature, the higher

the rate of discharge, the lower

the available capacity.

This relationship is illustrated in the above graph.

Applications Applications can be classified under two basic categories:

■ Standby (Float Charge)

■ Cyclic

A float application requires the battery to be on constant charge with an occasional discharge whereas in a

cyclic application the battery is charged and discharged on a regular basis.

Typical Applications of Power Sonic Products

Cap

acit

y R

atio

(%

)

Temperature (Deg C)

APPLICATION

Telecommunications ● ● ✔ ✔ ✔ ● ● ✔UPS/Standby Power ● ● ✔ ✔ ✔ ● ✔ ●Emergency Lighting ● ✔ ✔ ✔ ✔ ● ✔ ●Fire and Security ✔ ✔ ✔ ● ✔ ● ● ●Renewable Energy ● ● ✔ ✔ ● ✔ ● ✔Mobility ✔ ✔ ✔ ● ● ✔ ● ●General Electronics ✔ ✔ ● ● ● ● ● ●Utilities ● ● ✔ ✔ ● ● ● ✔

PS PS PG PG2v PG FT PSG (Gel) PSX OPzV, 2v Cells 5 Yr Life 10 Yr Life 6-12 Yr Life 15 Yr Life 12 Yr Life 10 Yr Life 6/10 Yr Life (Tubular Plate (VRLA) (VRLA) (VRLA) (VRLA) (VRLA) (VRLA) (VRLA) Gel)

BATTERYSERIES

● Contact Power-Sonic for fur ther application information

Self Discharge

Any charged battery tends to lose capacity over time. This capacity loss is referred to as Self Discharge and in

lead acid batteries occurs due to the inherent instability of lead and lead dioxide in the presence of sulphuric

acid. This results in the conversion of the cells active materials into lead sulphate which effectively discharges

the cell. The rate of conversion increases with temperature.

Overcharging

As a result of too high a charge voltage, excess current will flow into the battery after reaching full charge,

causing decomposition of water in the electrolyte and premature aging. At high rates of overcharge a battery will

progressively heat up. As it gets hotter, it will accept more current, heating up even fur ther. This is called thermal

runaway and it can destroy a battery in as little as a few hours.

Undercharging

If too low a charge voltage is applied, the current flow will essentially stop before the battery is fully charged.

This allows some of the lead sulphate to remain on the electrodes, which will eventually reduce capacity.

Batteries which are stored in a discharged state, or left on the shelf for long periods, will accept far less current

than normal. This is caused by a phenomenon called “sulphation”. Usually, the battery will star t to accept

increasing amounts of current until a normal current level is reached. If there is no response, even to charge

voltages above recommended levels, the battery may have been in a discharged state for too long to recover.

Self Discharge Characteristics

Cap

acit

y R

ete

nti

on

Rat

io (

%)

Storage Period (Months)


Connecting in SeriesWhen connecting batteries in series the positive terminal of the first battery is connected to the negative

terminal of the second battery and so on down the string.

Series connection

Connecting in ParallelWhen connecting batteries in parallel (positive terminals are connected to the positive terminal and negative

terminals to the negative), all batteries in the string will receive the same charge voltage but the charge current

each battery receives will vary until equalization is reached.

Parallel connection

Note: A series connection increases the over all voltage of the battery string and a parallel connection increases the capacity.

Basic Lead Acid Chemistry The basic electrochemical reaction equation in a lead acid battery can be written as:

Discharge

During the discharge por tion of the

reaction, lead dioxide (PbO2) is

conver ted into lead sulphate (PbSO4)

at the positive plate. At the negative

plate sponge lead (Pb) is conver ted

to lead sulphate (PbSO4). This causes

the sulphuric acid (H2SO4) in the

electrolyte to be consumed.

Charge

During the recharge phase of the

reaction, the cycle is reversed. The lead

sulphate (PbSO4) and water are

electrochemically conver ted to lead

(Pb), lead dioxide (PbO2) and sulphuric

acid (H2SO4) by an external electrical

charging source.

Figure 1: Chemical reaction when a battery is being discharged

Figure 2: Chemical reaction when a battery is being charged

Reacts with sulphuric acid to form lead sulphate.

With energy from the charging source, the lead sulphate is broken

down and with oxygen from ionised water, lead dioxide is deposited on the

positive electrode and lead is deposited on the negative electrode.

Reacts with sulphate ions to form lead sulphate.

H2SO4 H2O

H2SO4

Pb + 2H2SO4 + PbO2 PbSO4 + 2H2O + PbSO4 Porous Lead Sulphuric Acid Porous Lead Sulphate Water Lead Sulphate Active material Electrolyte Lead Dioxide Active material Electrolyte Active material of negative plate Active material of negative plate of positive plate of positive plate

PbO

2

Pb

PbO

2

Pb

H2O

Discharging

Charging

+––

+

6 volt @ 225 AH

12 volt @ 200 AH

12 volt @ 200 AH

12 volt @ 225 AH

6 volt @ 225 AH

12 volt @ 400 AH

+ –

+ –


10080

605040

30

20

108

654

3

2

15442363024

18

12

6 .01 .02 .03 .05 .07 .10 .2 .3 .5 .6 .8 1 2 3 4 5 6 8 10 20 30 40 50 60 80 100 200 300 500 1000

0.5AH

0.8AH

1.1AH

1.4AH

2.0AH

2.5AH

3.5AH

4.5AH

5.5AH

7.0AH

10.0A

H

18.0A

H

26.0A

H

35.0A

H

55.0A

H

75.0A

H

110.0

AH14

0.0AH

210.0

AH

2.3AH

2.9AH

5.0AH

6.5AH

8.0AH

12.0A

H

20.0A

H

40.0A

H

65.0A

H

hrs

min

Basic Battery Sizing The below graph may be used for determining the appropriate battery size for a par ticular application,

expressed in ampere hours of capacity.

Firstly ‘look up’ the required discharge current (plotted on the x-horizontal axis) and the required discharge

time (plotted on the y-ver tical axis). Where the current and time lines intersect, the diagonal Ah curve shows

the minimum capacity required for the application. It should be noted that this is only a guide line and in

practice, if the intersection point of the time & current does not fall exactly on a par ticular Ah curve, the next

higher value Ah curve should be used to determine the minimum battery capacity/size.

Discharge Current (amps)

Dis

charg

e T

ime

(h

rs)

FASTON4.75mm X 0.8mmquick disconnect tabs

INSULATED WIRE LEADSWith JST plug

F1

WL

T6 THREADED INSERT – 6mm STUD

16mm

M6

6mm


SPRING TERMINALSFully collapsible positive and negative contacts

F2

SPT12 THREADED INSERT – 5mm STUD

12mm

M5

6mm



F1

WL


16mm

M6

6mm



F2


12mm

M5

6mm



F1

WL


16mm

M6

6mm



F2


12mm

M5

6mm



F1

WL


16mm

M6

6mm



F2


12mm

M5

6mm



F1

WL


16mm

M6

6mm



F2


12mm

M5

6mm



F1

WL


16mm

M6

6mm



F2


12mm

M5

6mm



F1

WL


16mm

M6

6mm



F2


12mm

M5

6mm



F1

WL


16mm

M6

6mm



F2


12mm

M5

6mm

M5 SS Bolt

12mm DiameterBrass Insert

FT2

M6 SS Bolt


FT3

M6 SS Bolt


SS7

M8 SS Bolt


FT6

M5 SS Bolt


FT2

M6 SS Bolt


FT3

M6 SS Bolt


SS7

M8 SS Bolt


FT6

M5 SS Bolt


FT2

M6 SS Bolt


FT3

M6 SS Bolt


SS7

M8 SS Bolt


FT6

Discharge times reflect cut-off voltages which vary with the discharge current:

"C" = Capacity of battery

LOAD FINAL CURRENT VOLTAGE 0.05C 1.75V/Cell 0.10C 1.75V/Cell 0.20C 1.75V/Cell 0.50C 1.70V/Cell 1.00C 1.50V/Cell 2.00C 1.50V/Cell

Figure 3 shows capacity lines for major Power-Sonic battery models with different ampere-hour ratings. Amperage is on the

horizontal scale and the time elapsed is on the ver tical scale; the product of these values is the capacity.

Figure 3: Capacity lines for Power-Sonic batteries

Battery Capacity Selector

Ambient temp. 20°C (68°F)

Terminal Details

16mm 6mm

7.2m

m

6mm

6.5m

m

14m

m

20mm

M8

7mm

T7 TerminalT6 Terminal

T5 Terminal

18mm

M6

6mm

18mm

M6

6mm

19mm

21mm

M6

4mm

19mm

21mm

M6

4mm

T13 TerminalT11 TerminalT12 Terminal

M5 SS Bolt

12 mm DiameterBrass Insert

FT2

M6 SS Bolt


FT3

M8 SS Bolt


FT6


Examples of Applications

Power Sources

■ Back-up Power

■ Computers

■ UPS

Communications

■ GPS equipment

■ Marine communications

■ Telecommunication systems

Lighting

■ Emergency Lighting

■ Exit lights

■ Hand held lights

Security Systems

■ Burglar/Fire alarms

■ Monitoring alarms

■ Metal detectors

Automotive

■ Electronic memory accessories

■ Braking/fuel systems

Recreation

■ Fish finders

■ Ride-on-toys

■ Electrical bicycles/scooters

Portable Equipment

■ Audio-visual devices

■ Test and measuring equipment

■ Consumer electronics

Monitoring Equipment

■ Fiber-optic test equipment

■ Scientific Instruments

■ Weather Instrumentation

Agricultural

■ Livestock/game feeders

■ Containment fencing

Military

■ Aerospace

■ Aircraft instrumentation

■ Fire control systems

Miscellaneous

■ Invisible fences

■ DC power lifts

■ Floor scrubbers

■ Laser Products

■ Robotics

■ Adver tising signs

Battery ConstructionTerminals

Depending on the model, batteries come either with Faston type terminals made of tin plated brass, threaded

inser t type terminals of the same composition, or heavy duty flag terminals made of lead alloy. A special epoxy is

used as sealing material surrounding the terminals.

Plates (electrodes)

Power-Sonic utilizes the latest technology and equipment to cast grids from a lead-calcium alloy free of antimony.

The small amount of calcium and tin in the grid alloy impar ts strength to the plate and guarantees durability

even in extensive cycle service. In the charged state, the negative plate active material is pure lead and that of

the positive lead dioxide. Both of these are in a porous or spongy form to optimize surface area and thereby

maximizing capacity. The heavy duty lead calcium alloy grids provide an extra margin of performance and life in

both cyclic and float applications and give good recovery from deep discharge.

Electrolyte

Immobilized dilute sulphuric acid: H2SO4

Relief Valve

In case of excessive gas pressure build-up inside the battery, the relief valve will open and release the pressure.

The one-way valve not only ensures that no air gets into the battery where the oxygen would react with the

plates causing internal discharge, but also represents an impor tant safety device in the event of excessive

overcharge. Vent release pressure is between 2-6 psi and the seal ring material is neoprene rubber.

Separators

Power-Sonic separators are made of absorbant glass fibre mat with high heat and oxidation resistance. The

material fur ther offers superior electrolyte absorption and retaining ability, as well as excellent ion conductivity.

Container & case sealing

Case and cover are made of non-conductive ABS plastic with flammability rating to UL94-HB or UL94 V-O.

Depending on the model the case sealing is ultrasonic, epoxy or heat seal.

Non SLA Battery Types

Power-Sonic are also suppliers of primary Alkaline cells and rechargeable Nickel Metal Hydride and

Nickel Cadmium cell/batteries – fur ther information is available by request.


Material Safety Data Sheets (MSDS)

■ It is impor tant that you familiarise yourself with these prior to handling, installing and disposing of all batteries. If there are any questions raised from these please contact Power-Sonics’ technical depar tment.

Handling

■ Always wear insulated gloves when handling batteries; especially when connecting series and parallel groups of batteries.

■ Follow all precautions as described in our Material Safety Data Sheets (MSDS). This information is subject to change depending upon government legislation. Visit our website: www.power-sonic.co.uk for up-to-date copies of these.

■ If equipment is to be stored for a long period of time the batteries should be disconnected to avoid undue drain on the batteries and any potential for damage to the equipment.

Installation

■ Fasten batteries tightly and make provisions for shock absorption if exposure to shock or vibration is likely.

■ When installing the battery within a piece of equipment, fix it securely at the lowest practicable point.

■ Do not apply undue force to the terminal or bend them. Avoid applying heat to the terminals through processes such as soldering.

■ If soldering to the battery terminals is unavoidable it must be accomplished within 3 seconds, using a soldering iron no greater than 100 watts.

■ Do not place batteries in close proximity to objects which can produce sparks or flames, and do not charge batteries in an inver ted position.

■ Avoid exposing batteries to heat! Care should be taken to place batteries away from heat-emitting components. If close proximity is unavoidable, provide ventilation. Service life is shor tened considerably at ambient temperatures above 20°c.

■ To prevent problems arising from heat exchange between batteries connected in series or parallel, it is advisable to provide air space of at least 0.4" (10mm) between batteries.

■ Do not mix batteries with different capacities, different ages or of different makes. The difference in characteristics will cause damage to the batteries and possibility to the attached equipment.

■ Battery cases and lids made of ABS plastic can sustain damage if exposed to organic solvents or adhesives.

■ It is good practice to ensure that the connectors are re-torqued and the batteries are cleaned periodically.

■ Do not attempt to open up batteries. Contact with sulphuric acid may cause harm. Should it occur, wash skin or clothes with liberal amounts of water. Do not throw batteries into fire; batteries so disposed may rupture or explode. Disassembled units are hazardous waste and must be treated accordingly.

Important Do’s and Don’tsPower-Sonic rechargeable sealed lead-acid batteries are designed to provide years of dependable service. Adherence to the following guidelines will ensure that battery life is maximized and operation is trouble-free.

Gas RecombinationThe process by which oxygen gas generated from the positive plate during the final stage of charge is absorbed into the negative plate, preventing loss of water.

High Rate DischargeA very rapid discharge of the battery. Normally in multiples of C (the rating of the battery expressed in amperes).

ImpedanceThe resistive value of a battery to an AC current expressed in ohms (Ω). Generally measured at 1000Hz at full charge.

Internal ResistanceThe resistance inside a battery which creates a voltage drop in proportion to the current draw.

Negative TerminalThe terminal of a battery from which electrons flow in the external circuit when a battery discharges. See Positive Terminal.

Nominal VoltageThe normal voltage of a lead-acid battery is 2 volts per cell.

Open Circuit VoltageThe voltage of a battery or cell when measured in a no load condition.

OverchargeThe continuous charging of a cell after it achieves 100% of capacity. Battery life is reduced by prolonged overcharging.

Parallel ConnectionConnecting a group of batteries or cells by linking all terminals of the same polarity. This increases the capacity of the battery group.

PolarityThe charges residing at the terminals of the battery.

Positive TerminalThe terminal of a battery toward which electrons flow through the external circuit when the cell discharges. See Negative Terminal.

Rated CapacityThe capacity of the cell expressed in amphrs. Commonly a constant current for a designated number of hours to a specified depth of discharge at room temperature.

RecombinationThe state in which the gasses normally formed within the battery cell during its operation are recombined to form water.

Series ConnectionThe connection of a group of cells or batteries by linking terminals of opposite polarity. This increases the voltage of the battery group.

Self DischargeThe loss of capacity of a battery while stored in an unused conditions without external drain.

SeparatorMaterial isolating positive from negative plates. In sealed lead acid batteries the separator is absorbent glass fibre which holds the electrolyte in suspension.

SLA BatterySealed lead-acid battery, generally having the following characteristics: Maintenance-free, leak-proof, position-insensitive. Batteries of this type have a safety vent to release gas in case of excessive internal pressure build-up. Hence also the term: Valve regulated battery.“Gel Cells” are SLA batteries whose dilute sulphuric acid electrolyte is immobilised by way of additives which turn the electrolyte into a gel.

Service LifeThe expected life of a battery expressed in the number of total cycles or years of standby service to a designated remaining percentage of original capacity.

Shelf Life The maximum period of time a battery can be stored without supplementary charging.

Standby ServicesAn application in which the battery is maintained in a fully charged condition by trickle or float charging.

State of ChargeThe available capacity of a battery at a given time expressed as a percentage of rated capacity.

SulphationThe deposit of lead sulphate on the surface and in the pores of the active material of the batteries’ lead plates. If the sulphation becomes excessive and forms large crystals on the plates the battery will not operate efficiently and may not work at all.

Thermal RunawayA Condition in which a cell or battery on constant potential charge can destroy itself through internal heat generation.

Valve Regulated Lead Acid battery (VRLA)See SLA Battery listed above.

Glossary


The Batteries and Accumulators (Placing on the market) Regulations 2008 The above regulations come into force on 26th September 2008 and are the legislation the UK Government is required to have in place to transpose EU Directive 2006/66/EC within this country.

Summarised below are Power-Sonic Europe Limited’s obligations as a battery supplier regarding this legislation for placing batteries on the UK market.

Material ProhibitionsThe only material within any of the technologies we place on the market that is potentially prohibited is that of Cadmium, in our Nickel Cadmium batteries. There is potentially a prohibition for these batteries, which contain more than 0.002% of cadmium. However, the prohibition does not apply to por table batteries intended for use in the following categories, which is the intended use for our batteries:

(a) Emergency and alarms systems, including emergency lighting

(b) Medical equipment(c) Cordless power tools

Labelling to aid recyclingAll Power-Sonic products are labelled according to current legislative requirements. These are the requirements to apply the crossed out wheeled bin symbol along with the appropriate chemical symbol for the item. These symbols are of the requisite size and are visible, legible and indelible. The relevant symbols for our batteries are:

Pb – VRLA (SLA) batteriesCd – Nickel Cadmium batteriesNI – Nickel Cadmium batteries

There is no symbol as yet for alkaline batteries.

In addition to the above symbols, there will be a requirement by 26th September 2009 to show battery capacities. This is already shown on Power-Sonic batteries.

These regulations are designed to pave the way for producer responsibility to ultimately ensure the recycling of all batteries that reach their end of life – fur ther consultation on the precise strategies to be adopted in order to work towards this objective are expected later. Power-Sonic Europe Ltd has for some years been making voluntary arrangements for the collection of the vast majority of our waste batteries. This has been achieved by the provision of waste bins at customer premises for our main product (VRLA Batteries), where volumes are sufficient, or by arranging collection from customers for delivery to our UK premises where the amount are more modest.

WeightLead Acid Batteries are very HEAVY ! Take care when transpor ting, lifting and installing batteries. Also consider floor loadings of installations.

Sulphuric AcidElectrolyte is very corrosive. Flush any acid splashes from eyes and off skin with plenty of clean water. Seek medical aid immediately. Always wear safety glasses and protective clothing.

Electrical HazardBatteries are always live. Only use fully insulated tools. Remove all rings, watches, necklaces and always wear safety glasses.

Explosive gasesAlthough sealed cells and batteries vent significantly less gas than other forms of lead acid batteries, the gases vented will contain hydrogen and oxygen.

These gases normally diffuse rapidly into the atmosphere however if a charger fails, causing higher than recommended rates, substantial volumes of explosive gases will vent from the battery.

When the concentration of hydrogen exceeds 4%, the atmosphere becomes explosive. Note: gas is only generated when cells are on charge but also can be present during discharge.

Recycling For tunately, scrap lead acid batteries can be safely recycled. In fact they have been recycled since the 1920’s and today, lead acid batteries have a higher recycling rate than other waste products such as aluminium, paper and glass or plastic beverage containers.

For fur ther information, please see:

■ European directive 2006/66/EC on Batteries and accumulators and waste batteries

■ The Batteries and Accumulators (Placing on the Market) Regulations 2008

■ Reach (Registration Evaluation, Authorisation and restriction of Chemicals)

Battery Safety

Power-Sonic Sealed Lead Acid and Nickel Cadmium batteries conform to the European Council directive 2006/66/EC, which specifies that batteries containing mercury, lead or cadmium should be collected separately when spent and should carry an identifying WEE Symbol, a crossed-out wheelie bin and the appropriate chemical symbol. This is designed to inform the end user to separate batteries from other waste.

Power-Sonic Europe’s policy is to accept returns of our product at the customer’s expense and to ensure proper recycling, we then route the batteries through Environment Agency procedures using approved waste carriers and licensed sites.

European Directives WEEE 2002/96/EC and ROHS 2002/95/EC The ROHS directive covers the same scope as the WEEE directive. As Batteries and accumulators do not fall

into any of the ten categories listed by the WEEE directive our products are considered to be outside the scope

of each of these directives.


European Directive 2006/66/EC and UK Regulations on batteries and accumulators and waste batteries “The primary objective of this Directive is to minimize the negative impact of batteries and accumulators on the environment, thus contributing to the protection, preservation and improvement of the quality of the environment”. This statement quoted from item 1 of the Directive summarizes its main aim.

The broad aim of the Directive is to ensure correct labelling of the various technologies, and set and enforce targets for the collection and recycling of waste batteries of all types, thus providing ongoing improvements towards environmental protection and help prevent heavy metal pollution.

Member states have been required to produce legislation to meet the requirements of the Directive. There are currently two pieces of legislation in force in order to transpose the Directive in the UK. To read more information about this please visit www.power-sonic.co.uk/downloads and click on the EU Directive document link.

R.E.A.C.H. (Registration, Evaluation, Authorisation and restriction of Chemicals) This is a European regulation that came into force on June 1st 2007. A major aim is “to provide a high level of protection of human health and the environment for the use of chemicals”.1

Whilst the regulation is primarily aimed at the chemical industry and sales of individual chemical substances, its scope includes what the regulations term “preparations” and “ar ticles”. This latter term is wide ranging and can include cars, telephones – and batteries2. However, under the section “substances in ar ticles”3 the following statement effectively exempts Power-Sonic from the obligation of registration of its products with the European Chemicals Agency (ECHA): “…notification is not required… when exposure to humans and environment can be excluded during normal conditions of use, including disposal”.

Additionally, guidelines issued by “EUROBAT”, which represents the European automotive and industrial battery industry has produced extensive guidelines which declare the battery industry, as a “downstream user” as having no registration obligations4.

The guideline notes cer tain obligations that REACH defines for downstream users in their communications along the supply chain5. These involve the preparation and availability of EC safety data sheets. Power-Sonic Europe Ltd, has its Material Safety Data Sheets available on our website (www.power-sonic.co.uk under “downloads”) or on request from our offices.

Substance of Very High Concern (SVHC)For the latest PSE company statement on SVHC, please refer to ECHA Substances document available at the below link:http://www.power-sonic.co.uk/files/downloads.php

1. Health and Safety Executive website http://www.hse.gov.uk/reach/about.htm

2. Ibid.p.2

3. http://guidance.echa.europa.eu/substances_articles_en.htm

4. “Guidelines of EUROBAT for the Implementation of the European REACH Regulation Covering the Manufacture and Marketing of Batteries in the European Union – October 2008”, Section 3 – available from www.eurobat.org or on demand from Power-Sonic Europe Ltd.

5. Ibid. Section 4.1.

6. http://echa.europa.eu/doc/press/pr_08_34_msc_identification_svhc_20081009.pdf

summary tablesBattery type Page

PS Series, VO Series 22-23

PG Series 24-25

PSGL Series 26-27

PSX Series 28

OPzV Series 29

Non SLA Series 30-31


This is a selection of our most popular models only.If the product you require is not listed here, please contact us or refer to our website –


Terminal Types:

Please see page 13 or individual data sheets for the terminal types & size information.

Minimum orders of non-stock models:

PS range (38Ah and above) 100 pcs of any one model, <38Ah 500 pcs of any one model for special production of no-stock models.

MODEL DESIGN LIFE IN FLOAT

SERVICE AT 20°C

NOMINAL VOLTAGE

V

NOMINAL CAPACITY C20 (Ah)

APPROXIMATE DIMENSIONS (MM) PLEASE REFER TO INDIVIDUAL DATA SHEETS FOR FULL INFORMATION

STANDARD TERMINAL

TYPE

CARTON QUANTITY

L W H TH

PS-610 5 6 1 50 42 51 57 F1 20

PS-612ST 5 6 1.3 97 24 51 57 F1 20

PS-630ST 5 6 3.4 134 34 60 66 F1 20

PS-640 5 6 4.5 70 47 100 106 F1 20

PS-670 5 6 7 151 34 94 100 F1 10

PS-682 5 6 8 98 56 117 117 F1 10

PS-6100 5 6 10 151 51 94 100 F1 10

PS-1212 5 12 1.2 97 43 52 58 F1 20

PS-1221 5 12 2.1 178 35 60 66 F1 20

PS-1230 5 12 3.4 134 67 60 66 F1 10

PS-1242 5 12 4.5 90 70 101 107 F1 10

PS-1270 5 12 7 151 65 94 100 F1 5

PS-12120 5 12 12 151 98 95 101 F1 4

PS-12170 5 12 17 181 77 165 165 T12 2

PS-12260 10 12 26 166 176 125 125 T12 2

PS-12350 10 12 35 195 130 156 177 T5 1

PS-12380 10 12 38 197 165 170 170 T6 1

PS-12450 10 12 45 197 165 170 170 T6 1

PS-12550 10 12 55 229 138 205 226 T6 1

PS-12650 10 12 65 348 167 178 178 T6 1

PS-12750 10 12 75 259 168 206 215 T6 1

PS-121000 10 12 100 305 168 206 215 T6 1


SERVICE AT 20°C

NOMINAL VOLTAGE

V



STANDARD TERMINAL

TYPE

CARTON QUANTITY

L W H TH

PS-6120 V0 5 6 12 151 51 94 100 F1 10

PS-1208 V0 5 12 0.8 96 25 62 62 WL 20

PS-1212 V0 5 12 1.2 97 43 52 58 F1 20

PS-1221 V0 5 12 2.1 178 35 60 66 F1 20

PS-1230 V0 5 12 3.4 134 67 60 66 F1 10

PS-1242 V0 5 12 4.5 90 70 101 107 F1 10

PS-1270 V0 5 12 7 151 65 94 100 F1 5

PS-12120 V0 5 12 12 151 98 95 101 F1 4

PS-12180 V0 5 12 18 181 77 167 167 T12 2

PS-12260 V0 10 12 26 166 175 118 125 T12 2

PS-12400 V0 10 12 40 197 165 170 170 T6 1

PS-12700 V0 10 12 70 348 167 178 178 T6 1

PS Series, VO SeriesPS 6-12 Volt Monoblocs (5/10yr Life) UL94-V0 Flame Retardant Casing

Key:

Stocked item

Non-stocked item

Rev 1 (06/14)



PG range (38Ah and above) 100 pcs of any one

model, <38Ah 500 pcs of any one model for

special production of no-stock models.


SERVICE AT 20°C

NOMINAL VOLTAGE

V



STANDARD TERMINAL

TYPE

CARTON QUANTITY

L W H TH

PG12V5.4 6 12 5.4 151 51 93 99 F1 6

PG12V6 6 12 6 90 70 101 107 F2 10

PG12V7.6 6 12 7.6 151 65 94 100 F2 5

PG12V9 6 12 8.5 151 65 95 100 F2 5

PG12V14 6 12 14 151 98 95 101 F2 4

PG12V21 6 12 21 182 77 167 167 T12 2

PG12V28 12 12 28 165 125 175 175 T12 2

PG12V30 12 12 30 166 176 125 125 T12 1

PG12V45 12 12 45 197 165 170 170 T6 1

PG12V60 12 12 60 228 138 208 211 T6 1

PG12V65 12 12 65 259 168 208 214 T6 1

PG12V80 12 12 80 259 168 208 214 T6 1

PG12V100 12 12 100 305 168 207 213 T6 1

PG12V110 12 12 110 330 173 212 220 T11 1

PG12V130 12 12 130 410 177 225 225 T11 1

PG12V150 12 12 150 344 171 274 280 T11 1

PG12V160 12 12 160 485 170 240 240 T11 1

PG12V220 12 12 220 522 240 218 224 T11 1


SERVICE AT 20°C

NOMINAL VOLTAGE

V



STANDARD TERMINAL

TYPE

CARTON QUANTITY

L W H TH

PG-2V80 15 2 80 170 72 205 212 T6 1

PG-2V110 15 2 107 170 72 205 212 T6 1

PG-2V160 15 2 160 170 98 205 212 T7 1

PG-2V215 15 2 214 170 110 328 350 T11 1

PG-2V270 15 2 270 170 110 328 350 T11 1

PG-2V325 15 2 325 170 150 328 350 T11 1

PG-2V430 15 2 430 210 175 330 350 T11 1

PG-2V540 15 2 540 240 175 330 350 T11 1

PG-2V650 15 2 645 300 175 330 350 T11 1

PG-2V1100 15 2 1060 475 175 328 350 T11 1

PG-2V1300 15 2 1284 475 175 328 350 T11 1

PG-2V2700 15 2 2700 490 350 339 349 T11 1

PG SeriesPG Series: 6-12 Volt Monoblocs (6/12yr Life) PG Series: 2 Volt Cells (15yr Life)


SERVICE AT 20°C

NOMINAL VOLTAGE

V

C20 CAPACITY TO 1.8V/C (Ah)


STANDARD TERMINAL

TYPE

CARTON QUANTITY

L W H TH

PGFT12v110 12 12 110 508 110 238.5 238.5 T13 1

PGFT12v160 12 12 165 551 110 287 287 T6 1

PGFT12v180 12 12 180 560 126 280 280 T13 1

PG Series: 12 Volt Front Terminal Monoblocs (12yr Life)

Key:

Stocked item

Non-stocked item



Terminal Types:


Rev 1 (06/14)

POWER-SONIC BATTERY GUIDE 2726 POWER-SONIC BATTERY GUIDE26 POWER-SONIC BATTERY GUIDE

Minimum orders:

PSGL range – 100 pcs

of any one model for

special production.

MODEL NOMINAL VOLTAGE

V

C20 CAPACITY TO 1.8V/C

(Ah)


STANDARD TERMINAL

TYPE

CARTON QUANTITY

L W H TH

PSGL12170 12 17 181.5 77 167.5 167.5 T12 2

PSGL12260 12 26 166.5 175 125 125 T12 1

PSGL12300 12 30 195 130 164 180 T5 1

PSGL12380 12 38 197 165 170 170 T6 1

PSGL12450 12 45 257 132 200 200 T6 1

PSGL12500 12 50 229 138 211 211 T6 1

PSGL12600 12 60 325 167 174 174 T6 1

PSGL12650 12 65 325 167 174 174 T6 1

PSGL12700 12 70 259 168 208 214 T6 1

PSGL12850 12 85 305 168 207 213 T6 1

PSGL12960 12 96 330 173 212 220 T11 1

PSGL121100 12 110 410 177 225 225 T11 1

PSGL121300 12 130 344 171 274 280 T11 1

PSGL121350 12 135 485 170 240 240 T11 1

PSGL122000 12 200 522 240 218 224 T11 1

PSGL SeriesPSGL (Gel) Cyclic 12 Volt Monoblocs



Key:

Stocked item

Non-stocked item

M5 SS Bolt


FT2

M6 SS Bolt


FT3

M8 SS Bolt


FT6Triple Seal Detail

Epoxy seal (Red for +Black for –)

Plastic screwedcap to hold downflat and O-rings

Plastic flat ring

Rubber O-ring

Lead terminalpost with brassinsert

Rev 1 (06/14)

FOR CYCLIC PERFORMANCE CHARACTERISTICS PLEASE REFER TO BATTERY GUIDE SECTION

POWER-SONIC BATTERY GUIDE 2928 POWER-SONIC BATTERY GUIDE28 POWER-SONIC BATTERY GUIDE


PSX range (38Ah and above) 100 pcs of any one

model, <38Ah 500 pcs of any one model for

special production of no-stock models.


SERVICE AT 20°C

NOMINAL VOLTAGE

V

NOMINAL CAPACITY APPROXIMATE DIMENSIONS (MM) PLEASE REFER TO INDIVIDUAL DATA SHEETS FOR FULL INFORMATION

STANDARD TERMINAL

TYPE

CARTON QUANTITY

15MIN RATE WATTS TO 1.67V P/C

C20 CAPACITY TO 1.8V/C (Ah) L W H TH

PSX12-2.5 6 12 45.9 2.5 178 35 60 66 F1 20

PSX12-3.5 6 12 70.89 3.5 134 67 60 66 F1 10

PSX12-6.0 6 12 122.22 6 90 70 101 107 F2 10

PSX12-6.5 6 12 133.86 6.5 151 65 94 100 F2 5

PSX12-6.5S 6 12 151.92 6.5 151 51 92 98 F1 (neg) F2(pos) 6

PSX12-7.0 6 12 170.4 7 151 65 94.5 100 F2 5

PSX12-8.5 6 12 193.2 8.5 151 65 94 100 F2 5

PSX12-13 6 12 298.56 13 151 98 95 101 F2 4

PSX12-20 6 12 481.32 20 181 77 162 165 T12 2

PSX12-28 10 12 598.86 28 166 175 122 125 T12 2

PSX12-45 10 12 757.74 45 197 165 156 170 T6 1

PSX12-70 10 12 1382.28 70 348 167 162 178 T6 1

PSX12-80 10 12 1383.66 80 259 168 208 214 T6 1

PSX12-110 10 12 2136.54 110 330 173 212 220 T11 1

PSX12-130 10 12 2903.04 130 410 177 211 225 T11 1

PSX12-160 10 12 2925 160 485 170 225 240 T11 1

PSX12-215 10 12 4054.8 215 522 240 218 224 T11 1

PSX6-215 10 6 2027.4 215 322 178 228 234 T11 1

PSX SeriesPSX Series: 6-12 Volt Monoblocs (6-12yr Life)

Key:

Stocked item

Non-stocked item



Rev 1 (06/14)

Terminal Types:


Minimum orders:

PS-OPzVL range - 100 pcs of any

one model for special production.

OPzV Series2 Volt Cells (20yr Life) 2V Tubular Gel Batteries

Key:

Stocked item

Non-stocked item



Terminal Types:



SERVICE AT 20°C

NOMINAL VOLTAGE

V

NOMINAL VOLTAGE CAPACITY

@10HR RATE Ah


STANDARD TERMINAL

TYPEL W H TH

4OPzV200 20YRS 2 200 103 206 355 390 T11

5OPzV250 20YRS 2 250 124 206 355 390 T11

6OPzV300 20YRS 2 300 145 206 355 390 T11

5OPzV350 20YRS 2 350 124 206 471 506 T11

6OPzV420 20YRS 2 420 145 206 471 506 T11

7OPzV490 20YRS 2 490 166 206 471 506 T11

6OPzV600 20YRS 2 600 145 206 646 681 T11

8OPzV800 20YRS 2 800 191 210 646 681 T11

10OPzV1000 20YRS 2 1000 233 210 646 681 T11

12OPzV1200 20YRS 2 1200 275 210 646 681 T11

12OPzV1500 20YRS 2 1500 275 210 796 831 T11

16OPzV2000 20YRS 2 2000 399 210 772 807 T11


TYPE REF VOLTAGE

V

NOMINAL CAPACITY 0.2C (mAh)

TYPE DIMENSIONS (MM)

DIAMETER HEIGHT

NCDH4000 1.2 4000 D 32.2 59.5

NCDH40002C * 2.4 4000 D 32.5 118.4

NCDH40003C * 3.6 4000 D 32.5 178

NCDH40004C * 4.8 4000 D 32.5 237

NCDH40005C * 6 4000 D 32.5 296.5

NCDH40006C * 7.2 4000 D 32.5 356

NCDH40007C * 8.4 4000 D 32.5 415

NCDH40008C * 9.6 4000 D 32.5 475

L W H

NCDH40002A * 2.4 4000 D 64.50 32.50 60.50

NCDH40003A * 3.6 4000 D 97.00 32.50 60.50

NCDH40004A * 4.8 4000 D 130.00 32.50 60.50

NCDH40005A * 6 4000 D 163.00 32.50 60.50

NCDH40006A * 7.2 4000 D 196.00 32.50 60.50

NCDH40007A * 8.4 4000 D 229.00 32.50 60.50

NCDH40008A * 9.6 4000 D 262.00 32.50 60.50

Non SLA SeriesNickel Cadmium High Temperature Ni-Cad Pack Configurations

■ Standard Configuration Codes



Rev 1 (06/14)

Note: All dimensions are maximum. Those marked with * include sleeving.

Code: ACells arranged in a row

Code: ECells stacked in multiple columns & layers

Tag Types:

0 = Solder Tag

1 = Wire leads one end of battery

2 = Other terminations

3 = No tags, blank ends

4 = Single PC Tags both ends

5 = Single PC pin-double PC pin +

6 = Centre Wire +- solder tags

7 = Customers own connector assembly

8 = Double PC pn - single PC pin +

9 = Wire leads either end of battery

Code: BCells arranged in a horizontal rectangle

Code: FCells arranged in horizontal zig-zag rows (1+ layers)

Code: CCells stacked in vertical column

Code: GCells arranged in a horizontal triangle

Code: DCells stacked in multiple columns & layers

Code: HCells attacked in 2 vertical columns of unequal number of cells

In the event of further technical development we reserve the right to alter our design, specification and price without notice. E&O.E

POWER-SONIC CORPORATION (HQ) (USA)Power-Sonic Corporation7550 Panasonic WaySan Diego, California 92154United States

Tel: 1 (619) 661 2020Fax: 1 (619) 661 3650Website: www.power-sonic.com

POWER-SONIC EUROPE LIMITED (France)5-7 Avenue du Général De Gaulle60300 SENLIS

Tél: +33 (0)3 44 32 18 17Fax: +33 (0)3 44 32 18 18Email: [email protected]: www.power-sonic-fr.com

POWER-SONIC EUROPE LIMITED (UK)(European Head Office)3 Buckingham SquareHurricane WayWickford, Essex SS11 8YQ

Tel: Main Office: +44 (0)1268 560686Customer Service: +44 (0)1268 568571Sales & Marketing: +44 (0)1268 568572Fax: +44 (0)1268 560902Email: [email protected]: www.power-sonic.co.uk

Power-Sonic is dedicated to continual product development enabling us to offer solutions for all industry specifications

globally. We pride ourselves on product quality, performance and reliability, meeting the industry standards with VdS,

NCP and UL approvals.

Our batteries have superior performance characteristics which is achieved through advanced engineering and state of

the art manufacturing processes, coupled with the use of premium raw materials.

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