Lifeline GPL Series Technical Manual

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TECHNICAL MANUAL

For

Lifeline

Batteries

Manufactured by:

Concorde Battery Corporation

2009 San Bernardino Road

West Covina, CA 91790

Phone 626-813-1234

Fax 626-813-1235

www.lifelinebatteries.com

Document No. 6-0101

Revision G

November 26, 2019

NOTICE: The technical data contained herein has been reviewed and approved for general

release on the basis that it contains no export controlled information. No part of this document

may be copied or reproduced by any means, including electronic or mechanical, without written

permission from Concorde Battery Corporation.

DISCLAIMER: The technical data contained herein is based upon the best information available

as of the latest revision date. Concorde Battery Corporation makes no warranty of

merchantability, fitness for any particular purpose, or any other warranty, expressed or implied,

with respect to such information, and we assume no liability resulting from its use. It is the

obligation of each user of the product to determine the suitability for any particular application

and to comply with the requirements of all applicable laws regarding use and disposal of this

product.

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Page 1 TECHNICAL MANUAL ® Lifeline Batteries Manufactured by: Concorde Battery Corporation 2009 San Bernardino Road West Covina, CA 91790 Phone 626-813-1234 Fax 626-813-1235 www.lifelinebatteries.com Document No. 6-0101 Revision G November 26, 2019 NOTICE: The technical data contained herein has been reviewed and approved for general release on the basis that it contains no export controlled information.
Page 2 RECORD OF REVISIONS Revision Date Initial Release 10/27/08 Rev. A 3/25/09 Rev. B 9/09/09 Rev. C 7/18/11 Rev. D 4/14/14 Rev. E 2/02/17 Rev. F 5/06/19 Rev. G 11/26/19 Document No. 6-0101 Rev. G Page 2 of 40...
Page 3 SAFETY SUMMARY DANGER OF EXPLODING BATTERIES Lead acid batteries can produce explosive mixtures of hydrogen and oxygen. Take the following precautions: • Never install batteries in an airtight or sealed enclosure and make sure installation is adequately ventilated. • Charge batteries in accordance with the instructions given in this manual. •...
Page 4: Table Of Contents
Table of Contents Chapter 1 - Introduction 1.1 Company Background ……………………………………………………………………………. 5 ® 1.2 Overview of Lifeline AGM Technology ……………………………………………………….. 5 1.3 About this Manual ………………………………………………………………………………… 5 Chapter 2 - Battery Construction 2.1 Component Description ………………………………………………………………………….. 6 2.2 Battery with Cut Away View ……………………………………………………………………… 8 2.3 Terminal Types …………………………………………………………………………………….
Page 5: Chapter 1 - Introduction
Chapter 3 provides a comparison of Lifeline® with other lead acid technologies: flooded- electrolyte batteries, gelled-electrolyte batteries, and AGM batteries from other manufacturers. Chapter 4 presents an overview of the battery specifications for the Lifeline® product line; detailed specifications for each model are published separately. Chapter 5 provides instructions for storing, operating and servicing Lifeline®...
Page 6: Chapter 2 - Battery Construction
CHAPTER 2 - BATTERY CONSTRUCTION 2.1 Component Description Refer to the battery pictorial in Section 2.2 showing a cut away view of the cell and a summary of the features and benefits. A more detailed description of the battery’s construction is given below.
Page 7 The gasses that escape are mainly oxygen and some hydrogen, and these gasses rapidly dissipate into the atmosphere. TERMINALS - Lifeline® AGM batteries are available in a variety of terminal configurations. Most terminal types are made of copper alloy which provide a long lasting, low resistance electrical connection.
Page 8: Battery With Cut Away View
2.2 Battery with Cut Away View Document No. 6-0101 Rev. G Page 8 of 40...
Page 9: Terminal Types
2.3 Terminal Types Document No. 6-0101 Rev. G Page 9 of 40...
Page 10: Chapter 3 - Technology Comparison
One other difference is that flooded batteries can not tolerate freezing temperatures when in the discharged state, whereas AGM batteries are resistant to damage by freezing temperatures. The following table provides a side by side comparison of Lifeline® AGM and flooded deep cycle batteries.
Page 11: Lifeline ® Versus Gel Batteries
23% reduction in the cycle life. The charge acceptance of gel batteries is also less than that of Lifeline® AGM batteries. This means it takes longer to recharge gel batteries. As an example, tests have shown that when discharged to 50% of rated capacity (fairly common in a deep cycle applications), gel batteries take twice as long to reach full charge compared to Lifeline®...
Page 12: Lifeline ® Versus Other Agm Batteries
AGM Batteries ® Lifeline® AGM batteries have been specifically designed for true deep cycle, long service life capability in adverse temperature and handling conditions. Concorde uses extra thick positive plates, high density paste, thick AGM separator layers encased within a microporous polyethylene envelope, thick walled containers with epoxy-sealed covers.
Page 13: Chapter 4 - Battery Specifications
CHAPTER 4 - BATTERY SPECIFICATIONS 4.1 Battery Models Lifeline® Series consists of deep cycle as well as engine starting batteries. Capacities of the deep cycle batteries range from 33 to 1200 ampere-hours (rated at the 20-hour rate) and a variety of 2-volt, 6-volt and 12-volt models are available. Ratings of the starting batteries range from 550 amperes to 810 amperes (CCA at 0°F) and these are only available in 12-volt models.
Page 14: Chapter 5 - Commissioning And Servicing Instructions
CHAPTER 5 - COMMISSIONING AND SERVICING INSTRUCTIONS 5.1 Storage Lifeline® Batteries are charged at the factory before shipment to the distributor. For warranty coverage, batteries need to be properly boost charged while in storage and installed within 12 months of the original factory ship date. Batteries should be stored in the coolest environment available, preferably not exceeding 68°F (20°C).
Page 15 Figure 5-1. Series Connection Figure 5-2. Parallel Connection Figure 5-3. Series/Parallel Connection Document No. 6-0101 Rev. G Page 15 of 40...
Page 16 Connection options for 4-terminal batteries are illustrated in Figures 5-4 through 5-8. For low rate applications (current levels less than 400 amperes), only two of the four terminals need to be connected, but it is still best to use all four terminals for redundancy. For high rate applications (current levels greater than 400 amperes), all four terminals should be connected.
Page 17 Figure 5-7. Series/Parallel Connection for 4-Terminal Batteries (Low Rate Applications Only) NOTE: Cables A, B and C carry different current levels and should be sized accordingly. In this example, the current in Cable B is 2 times that of Cable A and the current in Cable C is three times that of Cable A.
Page 18: Discharging
Figure 5-8. Series/Parallel Connection for 4-Terminal Batteries (Low or High Rate Applications) 5.3 Discharging Discharge data for Lifeline® AGM batteries are given in Appendix C. The capacity delivered by the battery depends on the rate of discharge as well as the battery temperature. The battery will deliver less capacity as the discharge rate increases and less capacity as the temperature is lowered.
Page 19: Charging
“walk down” as it is cycled, resulting in sulfation and premature failure. The recommended method of charging Lifeline® AGM batteries is to use a 3-stage charging profile. In the first stage, a constant current is applied until the voltage reaches a pre-set limit.
Page 20 Due to the low impedance design, Lifeline® batteries can tolerate in-rush current levels as high as 5C (500A for a 100Ah battery). The time to reach full charge at temperatures in the range of 20- 30°C (68 to 86°F) can be estimated from the following equation:...
Page 21: Conditioning
Equalizing Charge is generally applied to flooded lead acid batteries that are susceptible to acid stratification. However, an Equalizing Charge may be used to provide a Conditioning Charge for Lifeline® batteries as described below. To apply a conditioning charge, first go through the normal charge cycle to bring the battery to full charge.
Page 22: Deep Discharge Recovery
5.7 Capacity Testing To determine the actual capacity of a Lifeline® AGM battery relative to its rated capacity, a full discharge test should be performed. Although there are various battery testers available on the market, such as carbon pile testers, impedance meters, conductance meters, and others, these testers are not reliable in determining the battery’s actual capacity.
Page 23: Temperature Considerations
5.8 Temperature Considerations The temperature of the battery has a significant impact on its performance and life capability. Battery capacity is reduced significantly in cold temperatures. For example, a battery that operates continuously at -18ºC (0º F.) will only provide about 60% of its normal room temperate capacity.
Page 24: Servicing
5.9 Servicing Lifeline® AGM batteries do not need electrolyte adjustment as do flooded lead-acid batteries, but periodic servicing is essential to assure continued integrity of the battery system. Servicing should include good record keeping to document the life history of the battery system and to identify whether corrective action needs to be taken.
Page 25: Cleaning
All local regulations and ordinances must be followed. Never discard Lifeline® AGM batteries in the trash or in a landfill. The recycle rate of lead-acid batteries is close to 100% and this is very good for the environment! Document No.
Page 26: Chapter 6 - Safety Information
As of this writing, Concorde does not know of any Lifeline® AGM batteries that have failed due to thermal runaway. To preclude the possibility of thermal runway, the charging instructions in Chapter 5 should be carefully followed, especially if the battery will be subjected to high ambient temperatures.
Page 27: Appendix A - Glossary
APPENDIX A – GLOSSARY OF BATTERY TERMS AGM - Stands for Absorbed Glass Mat. This is the separator system used in all Lifeline batteries. ® AGM Active Material - Electrode material which produces electricity during its chemical conversion. In the positive plate it is lead dioxide. In the negative plate, it is sponge lead.
Page 28 Current - The rate of flow of electricity. The movement of electrons along a conductor. It is comparable to the flow of a stream of water. The unit of measurement is an ampere. Cut Off Voltage - Battery voltage reached at the termination of a discharge. Also known as end point voltage or EPV.
Page 29 Trickle Charging - Method of charging in which the battery is either continuously or intermittently connected to a constant current charging source to maintain the battery in a fully charged condition. Not recommended for use with Lifeline batteries. ® AGM...
Page 30: Appendix B - Frequently Asked Questions
APPENDIX B – FREQUENTLY ASKED QUESTIONS (FAQ’S) 1. What does AGM stand for? It stands for Absorbed Glass Mat, the type of separator used in all Lifeline® AGM batteries. 2. What is the difference between AGM batteries and Gel batteries? Both AGM and Gel batteries utilize oxygen recombination and pressure relief valves to minimize water loss and allow maintenance-free operation.
Page 31 11. Do all the batteries in a series string have to be the same model/size? Yes. Do not mix different models/sizes of batteries in the same string. 12. Are there any issues with having parallel strings of different battery models/sizes, as long as each string has the same model/size battery in series? No, since the strings are in parallel they will operate at the same voltage level and will self-regulate.
Page 32 APPENDIX C – CHARTS AND GRAPHS Battery Load Voltage vs. DOD Below are listed the 1 hour, 8 hour, 20 hour and 120 hour load voltages during a discharge cycle to 100% discharge (10.5V endpoint) for a 12V battery at 77°F (25°C). DOD (%) 1 hr.

This manual is also suitable for:

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Lifeline GPL Series Technical Manual

Chapter 1 - Introduction

Chapter 2 - Battery Construction

Chapter 3 - Technology Comparison

Chapter 4 - Battery Specifications

Chapter 5 - Commissioning and Servicing Instructions

Chapter 6 - Safety Information

Appendix A - Glossary

Appendix B - Frequently Asked Questions

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