UNIKOR BATTERY CO.,LTD.

www.ukbkorea.com

MXVOLTA BATTERY
TECHNICAL &
HANDLING
MANUAL
 CONTENTS

1. WHAT IS MXVOLTA BATTERY ----------------------------

2. CHARACTERISTICS P. 3
2.1 Oxygen recombination reaction -----------------------
2.2 Prevents generation of hydrogen gas from negative pole P. 3
2.3 Prevention of gas generation by adjustment of charging P. 4
voltage -----------------------------------------
2.4 Principle of preventing liquid leakage ------------------- P. 4
2.5 Principle of self-electric discharge --------------------- P. 5
3. BEFORE USING P. 5
3.1 Unloading and checking -----------------------------
3.2 Installation and connection --------------------------- P. 7
3.3 Operational test and recharge ------------------------- P. 7
4. DAILY INSPECTION AND SERVICING P. 7
4.1 Treatment ----------------------------------------
4.2 Discharge ---------------------------------------- P. 8
4.3 Charge ------------------------------------------ P. 8
A. MONTHLY CHEKING ----------------------------------- P. 9
B. 6MONTHLY CHECKING --------------------------------- P.11
C. CHECKING ANNUALLY --------------------------------- P.11
D. SAFETY OF HANDLING -------------------------------- P.12
REFERENCE GUIDE P.12
*MXVOLTA battery discharge performance data -----------------
*Storage and manage MXVOLTA batteries --------------------- P.15
*General charge range -------------------------------- P.20
*List of material for MXVOLTA batteries ----------------------- P.21
P.22
1. WHAT IS MXVOLTA BATTERY ?

MXVOLTA battery is a kind of sealed batteries with maintenance free.

Generally, it still needs to add pure water regularly in order to keep a battery efficiency. Even
though the capacity of battery having been reduced due to self discharge, MXVOLTA battery
has a circulation system to re-fill in its function automatically and will not get any bad
influence in spite of using a long period of time.
As it is, no need to add pure water for MXVOLTA battery because we made MXVOLTA battery
minimized to generate gas such as H2, O2 in the battery, which are changed into water
automatically.

2. CHARACTERISTICS OF SEALED BATTERY

2.1 Oxygen recombination reaction.

It is to solve the problems of the gas generated in charging the sealed lead acid battery,
incidental acid mist, liquid leakage and refill water and its theory is as follows:

Flooded Recombination

Reaction Formula
① Oxygen is produced in the positive plate in overcharge.
H2O→2H+ + 1/2 O2 + 2e
② The oxygen is diffused to the negative plate thorough the separator.
③ The oxygen combination with lead in the negative plate
Pb + 1/2O2 → PbO
④ The oxidized lead in the negative plate makes water by bonding with sulphuric acid for
a certain amount of lead to be in the discharged condition.
PbO + H2SO4 → PbSO4 + H2O
⑤ The discharged lead is to be in the new charged condition electrically and chemically to
form a complete cycle.
PbSO4 + 2H+ + 2e → Pb + H2SO4
Offsetting the right and the left, it become the original condition. That is, water
disappeared in the 十pole, is produced in 一pole.
For this, the generation of hydrogen gas in 一pole should be controled. It is possible by
reducing the hydrogen generation voltage(hydrogen overvoltage), which is possible by using
the calcium alloy as the existing antimony alloy cannot perform it.

2.2 Prevents generation of hydrogen gas from negative pole

The existing lead-antimony battery generates much hydrogen from negative pole when
charging it and this is due to less excessive voltage by generation of hydrogen on alloy plate
of lead and antimony. When charging VRLA battery the over voltage of hydrogen generating
was largely reduced by use of alloy grid of lead & calcium instead of alloy of lead &
antimony and with this the generation of hydrogen could be largely reduced.

2.3 Prevention of gas generation by adjustment of charging voltage.

To restrain or prevent from gas generation by causing not to be enhanced to the gas
generating point by charging voltage by setting forth ceiling of charging voltage of VRLA
battery. The ceiling voltage of charging VRLA battery is 2.46V/Cell (maximum 2.50V/Cell)
and prevent from gas generation so that charging voltage of any more may not be enhanced
and that takes in-charge of decisive role to enable this is the grid used lead & calcium.
The existing lead antimony battery generates more gas of 5-8 times than the VRLA battery
by charging voltage of 2.46V/Cell. In case VRLA battery extremely small amount of gas
generates out of charging voltage of 2.50V/Cell however, gas is not emitted outside of
battery because of this reduces to water again through gas recombination reacting process.
2.4 Principle of preventing liquid leakage

a. Complete sealed structure

VRLA battery is structurally completely airtight under the normal atmosphere. Especially,
vent hole is mechanically tight by valve and the safety valve was mounted with pressure
adjusting function if excessive pressure is filled inside of the battery taking into account of
safety.

b. Free move prevention structure of electrolyte

The electrolyte inside of battery is completely absorbed by glass fiber mat or gel which
absorption of liquid is very good and cannot freely move within the battery. Since therefore,
there is no worry about leakage of liquid as there is no electrolyte freely move even if the
battery is laid down or upside down.
2.5 Principle of self-electric discharge
The self-electric discharge phenomenon of lead-acid battery is by interaction between
active material of negative pole and electrolyte and the element incurs self-electric
discharge are largely classified into two(2) sorts as follows:
(a) Constituents consist electrolyte (hydrogen ion in sulfuric acid)
(b) Impure substances contained in electrolyte

Out of the two sorts above a is unremovable element but (b) is removable but (a) that is to
say the electrolyte itself cannot be eliminated and so, the electric discharge phenomenon by
lead battery cannot completely be restrained. However, electric discharge volume may be
reduced. VRLA battery has very small electric discharge volume than the existing lead
antimony battery and this is because of use of alloy of lead & calcium in lieu of alloy of lead
& antimony as the grid material. The plate alloyed by lead & calcium has very big resistance
against electric discharge. On the alloy grid surface of lead & calcium the sponge lead
which is negative pole active material is not easily discharged electricity since hydrogen is
difficult to be generated (high hydrogen over voltage)
For your information the electric discharge principle by hydrogen ion in electrolyte is as
follows:
(-) pole - hydrogen ion in electrolyte
2H+ + 2e ---→ H2(gas) ------------------------- (1)
(-) pole - lead which is active material
Pb + H2SO4 --→ PbSO4 + 2H+ + Ze -------------- (2)
To sum up (1) reaction & (2) reaction
Pb + H2SO4 --→ PbSO4 + H2 ↑
(charged condition) (discharge condition)

3. BEFORE USING
Please read following specification before using.
When we release the battery to the users, the battery keep initial charged state which can be
generated of flammable gas. Don't short each connection before sufficient ventilation of
Installed places and just keep it away from fire in order to prevent dangerous factors.
3.1 Unloading and checking
3.1.1. When unloading the batteries, check the batteries in appearance and secure the
batteries firmly to protect it from impact.
3.1.2. After unloading, it needs to check followings.
a. Check the number of batteries, accessaries and its status in appearance.
b. Check open circuit voltage (over 2.1 Volt / cell)

3.2 Installation and connection

3.2.1. The installation places should be clean and keeping the temperature between IO℃
and 35℃.(Read the reference Figure 2. which shows the capacity of battery depends on
temperature)
3.2.2. When placing the battery, take suitable places and right upside in equipment.
3.2.3. Make sure to clean the battery connections before joining it with electric wire.
3.2.4.
a. In case using several batteries in series,the terminals should be correctly connected
To pay keen attention is needed not to short each other while connecting it.
b. When series connection, take the positive plate(+) to the negative plate(-) of next
connection battery. Never short it as batteries furnished with charged status.

#. Recommended torque for connecting bolts and nuts are :

Size of Bolt & Nut Torque

M6 Bolt 11±1 N.m
M8 Bolt 20±2 N.m
M10 Bolt 30±3 N.m
M10 Nut 18±2 N.m

c. After connecting, painting anti rust material slimly, having putted on safety cover on
the plate battery.
d. And then, take to connect the battery to a load or a charger.
The positive plate(+) of battery should be joined with the positive plate(+) of a load
or a charger and the same way to join it with negative parties.

3.3 OPERATIONAL TEST AND RECHARGE

3.3.1. Operation test
Please test the battery efficiency after joining with a load or a charger.
3.3.2. Recharge
As the battery can be in self discharge while transportation or storage period, the battery
should be recharged as following way.
a. After Charging on 2.4 Volt / Cell of 3 hours to 5 hours,
b. The charge should be changed to float charging voltage.
4. DAILY INSPECTION AND SERVICING
In order to maintain battery life span long and to use high power battery efficiently, to pay
heed is needed as below points.

4.1 Treatment
4.1.1. Maintain the numerical value of the regulations for float charging voltage.
4.1.2. Avoid operation of the battery with over 45℃
(The battery life span will be shorten in high temperature like over 45"C)
4.1.3. We recommend providing a vent hole to ensure ventilation.
4.1.4. keeps clean and dry conditions.
Never use any flammable liquid such as gasoline, benzene, etc to wash the container of
battery.

4.2 Discharge
4.2.1 DISCHARGE CHARACTERISTICS
a. The variation of time of duration according to discharge current
The capacity fully charged state effects 100% of capacity with law current discharge of. 20
hours case. Increasing voltage causes shorten time duration of discharge as Figure I shows.
* Note : C means nominal capacity with 20 hours rate. (Figure shows 6 Volt battery)

Figure 1. The variation of time of duration according to discharge current

b. Temperature and variation

The battery capacity beyond 20℃ caused increase in the apparent capacity, having
decreased the capacity below 20℃.
Figure 2 shows 100% capacity when 20 Hours rate discharge at 20℃, 106% capacity at -
20℃.

Figure 2. Temperature and the variation of capacity

c. For discharge current and final discharge voltage, please refer catalogue.
d. Precaution when discharging
 Take discharging at an ambient temperature of -20℃ to +35℃.
The capacity to hold a charge may not be recovered if the battery is left discharged for a
long period.
The battery should be immediately recharged if discharged deeply and or after using it.
The discharge capacity is affected by the discharge current. Evidently, increasing
discharge current causes decrease in the capacity, decreasing discharge current causes
increase in the capacity. ( Refer Figure 1. )

4.3 Charge
4.3.1 CONSTANT VOLTAGE CHARGE (Recommend to use constant voltage charger)
This type of charging generally employs a constant voltage constant current method with
current limitation to prevent the initial current from increasing, using a charger which
controls electric current by transistor.
As a lot of electric current needs during charging of initial current to the middle current,
electric current redcoats rapidly because being charge constant voltage at the last period of
charging.
At the last period of charging, keeps to charge constant voltage with reduced electric
current rapidly.
The setting value of constant voltage Is 2.4 Volt/Cell for cycle service.
The zone between 2.24 Volt/cell and 2.28 Volt/Cell are adopted for float charging.
The 2.23 Volt/Cell is a minimum charge value in order to maintain battery capacity after
fully charging.

Figure 3. Characteristics of constant voltage charging

Note : A charge quantity of 120% of discharge quantity is needed to fully charge the battery
a. Float charge
? Keep charging constant voltage with 2.23 Volt - 2.28 Volt/Cell at 25℃
Numeral value of temperature ; Vc, t = Vc, 25- 0.00033 ( t - 25 )
Vc,t ; Charging voltage at t℃
Vc. 25 ; Charging voltage at 25℃
? Initial current charging Is below 0.4 C
C : Nominal capacity A : Ampere
Ex) In case of 100 AH as battery capacity : 100 × 0.4 = 40 A
? Ambient temperatures are between 0℃ and 35℃
? Battery life will be shorten if high temperature charging.

b. cycle
? The constant voltage charge method is recommended to charge this battery.
? The charging voltage is between 2..4V and 2.5V/Cell as average.
? Constant current charge initially is with current remitted to 0.4C.
? As it is hardly possible to check the .tine charged full, we recommended using a timer to
be automatically stopped or the charger to be changed to float charging.

c. Precaution when charging

? The vent value should not be sealed.
? Always take the nominated voltage .
? Over Charging : shorten battery life
? When the temperature is over 45℃, please reduce electric current or ventilate the room
where is stored of battery.
 < The following points are needed to check regularly and please take note as record >

A. MONTHLY CHECKING (or 1 time per bi-week in case sensitive equipments needed for
high quality electric powers)
Check point Description Standard Arrangement

Total voltage of battery The voltage of volt Flat voltage × the Arrange the number of
while float charging meter number of cell cell by the float voltage
ex) 6cell for 12V charging

Battery room Battery room 1. Keep dry & clean a. To keep it dry and
Subsidiary Facilities a. Condition with 10～35℃ clean as temperature
b. Ventilation equipment 2. Operate normally with 10～35℃
b. Abnormal operation
cases, take mending
or change

B. 6MONTHLY CHECKING
Checking point Description Standard Arrangement

Battery room & a. State of vent valve a. Never close vent a. Remove dust from
subsidiary facilities b. Safety facilities like valve remove dust vent valve and vent
fire extinguisher b. State of connection hole
c. State of connection between charger and b. Check the rafty
connect cable facilities
c. Tighten connection
never short the
terminals

Appearance a. Broken container crack a. In case broken

& damage container, crack &
b. Dust of container in damage, please
appearance contact
us
b. Remove dust with
water, not gasoline or
flammable liquid

C. CHECKING ANNUALLY
Checking point Description Standard Arrangement

Connections State of connection Normal operation Checking tight state of

connection as well as
removing rust on the
terminals
D. SAFETY OF HANDLING
VT batteries are maintenance-free electrochemical systems designed to provide years of
trouble-free electrical energy. The performance and service life of these batteries can be
maximized by observing the following guidelines:

① Heat kills batteries. You must avoid placing batteries in close proximity to heat sources of
any kind. You will enjoy longer service life, if batteries are operated in ambient temperature
ranges of 20℃(68° F)

② Since the batteries may generate ignitable gas, please do not install them close to any
item that produces sparks.

③ If the battery is to be used in an enclosed space or in a container, provision should be

made for adequate ventilation.

④ As the battery containers and covers are made of ABS plastic resin, placing batteries in
an atmosphere of, or in contact with organic solvents or adhesive materials should be
avoided.

⑤ Permissible operating temperature range of battery is -20℃ to 50℃, but using within an
operating range of 5℃ to 35℃ will extend service life.

⑥ Use shock absorber and fasten battery firmly when heavy vibration of shock is expected
during service.

⑦ When connecting the batteries, free air space must be provided for each battery. The
recommended minimum space between batteries is 0.02 inches(5mm) to 0.04(10mm)

⑧ Clean the battery with a piece of wet cloth. Never have the battery splashed of deposited
with oils or organic solvents such as gasoline or paint thinner, nor have it cleaned with cloths
impregnant with these materials.
⑨ Dismantling the battery is not advisable. If sulphuric acid is deposited on skin or clothes,
please wash well with sufficient amount of fresh water and obtain immediate medical
attention.

⑩ A battery is liable to rupture if thrown into fire. Please avoid such conduct at all times.

⑪ Touching electrically conductive parts might result in an electric shock. Be sure to wear
rubber gloves before inspection or regular service.

⑫ Mixed use of batteries with different capacities, histories and/or manufactures is liable to
cause damage to the battery or the equipment. If this is unavoidable, please consult
manufacturer beforehand.

Should you have any other question, please feel free to contact UNIKOR BATTERY CO., LTD.
at any time of your convenience. www.ukbkorea.com
 REFERENCE GUIDE

* MXVOLTA battery dischagre performance data

* Storage and manage MXVOLTA batteries
* Troubleshooting flowchart
* List of material for MXVOLTA batteries
* Discharge capacity varies depending on the discharge current & hour rate
* STORAGE AND MANAGE OF MXVOLTA BATTERIES

A. O.C.V manage during storage at 25℃

Passed period VT2100 VT12012 VT1231
after to to to
manufactured VT23000 VT1224 VT12200
1 day - 1 month 2.12 ~ 2.11 V 12.90 V 12.80 V
1 month - 2 month 2.11 ~ 2.10 V 12.85 V 12.78 V
2 month - 3 month 2.11 ~ 2.10 V 12.80 V 12.75 V
3 month - 4 month 2.10 ~ 2.09 V 12.70 V 12.65 V
4 month - 5 month 2.10 ~ 2.09 V 12.65 V 12.60 V
5 month - 6 month 2.09 ~ 2.08 V 12.60 V 12.55 V

When passed more than 6 months, refresh charge must be carried out

B. When passed more than 6 months after manufactured, refresh charge

methods are two following
(1) Constant voltage
-------------------------------------------------
setting voltage Initial limit current Charging time
-------------------------------------------------
2.45V/cell 0.25 C 6±1 hour
-------------------------------------------------

(2) Constant current

-------------------------------------------------
setting current Charging time
-------------------------------------------------
0.05 C 6 ± 1 hour
0.1 C 3hour ± 30min.
-------------------------------------------------
GENERAL CHARGE RANGE

A suitable method of charging is the constant voltage characteristics method, whereby the current
intensity is initially held constant while the battery voltage rises until a voltage of 2.23 or 2.40V/cell
respectively is reached. From this point onwards. the voltage is held constant and charging proceeds
with tapering current when the voltage reaches 2.40V/cell one most switch over to 2.23V/cell.

% of C10 CHRG 2.23 V/CELL 2.40 V/CELL

DCHG. period
0.5x I10 1x I10 1.5x I10 2x I10 0.5x I10 1x I10 1.5x I10 2x I10
3h 87.5 94.0 95.0 96.0 87.5 96.0 98.0 98.0
6h 94.0 96.0 97.0 97.0 98.0 99.0 99.0 100.0
25 %
10 h 96.0 97.0 97.5 97.5 100.0 100.0 100.0 -
20 h 97.0 98.0 98.0 98.0 - - - -
3h 62.5 75.0 82.0 85.0 62.5 75.0 87.5 90.0
6h 75.0 89.0 90.0 92.0 75.0 93.0 96.0 97.0
50 %
10 h 90.0 93.0 93.0 94.0 91.0 98.0 98.0 98.0
20 h 97.0 95.0 95.0 95.0 100.0 100.0 100.0 100.0
3h 37.5 50.0 62.5 68.0 37.5 50.0 62.5 75.0
6h 50.0 73.0 80.0 83.0 50.0 75.0 88.0 90.0
75 %
10 h 66.0 86.0 88.0 89.0 66.0 91.0 96.0 96.0
20 h 93.0 93.0 93.0 93.0 95.0 100.0 100.0 100.0
3h 12.5 25.0 37.5 47.0 12.5 25.0 37.5 50.0
6h 25.0 50.0 65.0 70.0 25.0 50.0 76.0 80.0
100 %
10 h 41.5 73.0 78.0 80.0 41.5 83.0 87.0 90.0
20 h 80.0 91.0 91.0 91.0 83.0 98.0 100.0 100.0

The table shows the % capacity once more available after each relevant period given, taking the
charging factor(1.20) into consideration.
* List of material for VRLA battery

No. Part's Name Material of Construction MFG.

Method
1 Container & cover * ABS synthetic resin Injection
& top cover * Retains sufficient mechanical strength to molding
withstand battery internal pressure

2 Rubber vent cap * Synthetic rubber with acid resistance Injection

No leakage at 2.5psi molding

3 Ceramic filter * Vent plug provided with builtin Ceramic filter Injection
* Prevents ignition entering battery molding
* Prevents acid fumes from escaping from the *Appication
battery : More than
12V 65Ah to
4 Separator * Absorptive glass mat with heat oxidation 2V3000Ah
resistance and enough water absorbed height
Casting
5 Positive plate * Ca-Sn-Al alloy lead milling/
a)Grid * Pure lead mixing
b)Active material * Sulfuric acid pasting
* Water
* Fiber flock
Casting
6 Negative plate * Ca-Sn-Al alloy lead milling/
a)Grid * Pure lead mixing
b)Active material * Sulfuric acid pasting
* Water
* Fiber flock
* Expander(Mixed:Lignin, Carbon,
Barium sulfate)
No. Part's Name Material of Construction MFG.
Method
7 Intercell strap * Sn-alloy lead Casting

8 Electrolyte * Dilute sulpuric acid in quantity to preclude free

elctrolyte

9 Post terminal * Sn-alloy lead Casting

* Terminal Section employs dual complete seal
construction of O-ring and sealing of epoxy resin

10 O-ring * Synthetic rubber Injection

molding
11 Container & cover * Epoxy resin with acid resistance and high
boding agent adhesion strength

12 Bolt,nut and * SUS-304 material with acid resistance

washer

13 Connector * Cable wire or copper bar with lead coating Application

: only 2V
series cell

14 Connector cover * Synthetic resin (Injection molding) ditto

15 Post terminal * Synthetic rubber (Injection molding) ditto

cover

16 Battery rack * Rack made of steel Application

* Vertical or horizontal type of horizontal
* Acid-proof painting type : up to
* Earth quake - Proof and vibration - proof 2V600Ah
construction cell
DISCHARGE CAPACITY VARIES DEPENDING ON THE DISCHARGE CURRENT & HOUR RATE ( MxVolta
12V Medium & 2V Milenia large size battery)

HOUR-RATE DCHG CURRENT BATTERY EFFICIENCY

10 HRS 0.1000000 C 10 x 0.1000000 = 1 x 100 = 100.0000%
9 HRS 0.1089375 C 9 x 0.1089375 = 0.9804375 x 100 = 98.0438%
8 HRS 0.1190500 C 8 x 0.1190500 = 0.9524 x 100 = 95.2400%
7 HRS 0.1336200 C 7 x 0.1336200 = 0.93534 x 100 = 93.5340%
6 HRS 0.1514500 C 6 x 0.1514500 = 0.9087 x 100 = 90.8700%
5 HRS 0.1733000 C 5 x 0.1733000 = 0.8665 x 100 = 86.6500%
4 HRS 0.2092000 C 4 x 0.2092000 = 0.8368 x 100 = 83.6800%
3 HRS 0.2740000 C 3 x 0.2740000 = 0.822 x 100 = 82.2000%
2 HRS 0.3676000 C 2 x 0.3676000 = 0.7352 x 100 = 73.5200%
1 HRS 0.6494000 C 1 x 0.6494000 = 0.6494 x 100= 64.9400%
45 MIN 0.8248000C 45/60 x 0.8026000 = 0.6019 x 100 = 60.1950%
30 MIN 1.0000000 C 30/60 x 1.0000000 = 0.5 x 100 = 50.0000%
20 MIN 1.2410000 C 20/60 x 1.2410000 = 0.413667 x 100 = 1.3667%
10 MIN 1.6180000 C 10/60 x 1.6180000 = 0.2696667 x 100 = 26.9667%
5 MIN 1.8900000 C 5/60 x 1.8900000 = 0.1575 x 100 = 15.7500%
1 MIN 2.1410000 C 1/60 x 2.1410000 = 0.0356833 x 100 = 3.5683%
0.5 MIN 2.1650000 C 0.5/60 x 2.1650000 = 0.0180417 x 100 = 1.8042%
"C" stands for discharge current equivalent to the rated capacity at 10 hour rate.

RELATIONSHIP OF DISCHARGE CURRENT TO FINAL DISCHARGE VOLTAGE

DCHG CURRENT CUT OFF VOLTAGE

12V SERIES 6V SERIES 2V SERIES
0.1C or below current 11.40V 5.70V 1.90V
0.1C or current close to it 10.80V 5.40V 1.80V
0.16C or current close to it 10.50V 5.35V 1.75V
0.23C or current close to it 10.20V 5.10V 1.70V
0.6C or current close to it 9.60V 4.80V 1.60V
From 0.6C to 3C 9.00V 4.50V 1.50V
Current in excess of 3C 7.80V 3.90V 1.30V