The big problem of keeping SLAs on permanent float charge, typically
the case for UPSes and _anything_ that acts as a UPS, is avoiding
excess float voltage across any one cell in the string (6 cells in the
case of 12v lead acid batteries - or 24 cells in total for the battery
pack used by my venerable SmartUPS2000, currently bypassed until I can
get hold of a suitable set of batteries at a seriouly low price).
Getting the float charge voltage per cell on each and every cell in
the string can be nigh on impossible, especially when using multiples
of 12v batteries to provide the higher voltages (24, 36 and 48 volts).
The 2.3v per cell float charging voltage is a compromise between
sulphation and corrosion. Too low and you risk sulphation. Too high
and you increase the rate of corrosion (excessive voltage also
increases the risk of water loss).
To further complicate the 'ideal voltage' level, this is also
effected by temperature which, according wikipedia, requires a
-0.0235v adjustment for each deg C increase above the 20 deg C
reference standard for a 6 cell (12v) battery.
You might think that the typical 5 year service life of an SLA
battery pack in UPS service is unimpressive but, if you care to
substitute the UPS SLAs with car batteries, you'll swiftly change your
mind (usually after a mere six months of continous float charge and a
small fortune in de-ionised water).
I know this only too well from experience, three experiments in
total! The first 'experiment' was keeping a single 12v car battery
charged from a 13.8v CB powerpack to allow not only battery backup but
also to serve the high current demands of a "Burner". I didn't realise
this actually was an experiment at the time. It took the 20/20 vision
of hindsight to reach this conclusion over 20 years later. At the
time, I simply put this down to the 'bad luck' of using a defective
battery.
When I got my hands on the SmartUPS2000 at a radioham rally about a
decade back, it didn't have the seperate clip on battery box so I had
to use an external battery pack. I think I used a pack of four 7AH
12v SLAs to begin with. Since the orginals specified 17AH SLAs, I
investigated a cheaper option in the form of a set of 36AH car
batteries for a mere 60 quid from a local automotive dealer.
Initial testing results with these bad boys wired in parallel with
the SLAs were very encouraging indeed but the batteries gradually got
more and more 'thirsty' over the following months before developing
low voltage cells due to excessive self discharge effects which,
effectively, rendered the whole battery pack useless after only 6
months or so.
By then, I'd managed to accumulate a complete set of 24AH SLAs to go
with the 7AH ones. I didn't rush back out to my friendly automotive
dealer straight away for yet another battery bargain, that second
experiment didn't happen until maybe 6 to 12 months later (the penny
_still_ hadn't dropped that I had run 'The Experiment' for a second
time). Extremely annoyingly, the 'new' set of car batteries suffered
exactly the same fate 6 months or so later.
Only then did it occur to me that in spite of the more 'benign
charging regime', a total lack of vibration and extreme variations of
temperature such batteries seemed well able to cope with, there was a
fundamental problem in using such batteries as UPS backup power.
It was only then that, like Milton's frisbee, it struck me! I finally
realised that I had experienced exactly the same problem more than two
decades ago with that aforementioned battery and CB 'charger/PSU'
setup. Only then did I shy away from "The Cheap Car Battery Solution".
I strongly suspect the main problem was the sustained float charging
voltage that was causing corrosion in the paste filled plates and I am
tempted to experiment again, only this time reduce the 13.8v per 12v
battery down to 13.5v. I'd need to find another set of car batteries
at a bargain price yet again before investing in a fourth experiment
though.
Another alternative would be to try a set of deep cycle
leisure/marine batteries (again, only if I can find a trader prepared
to sell me them at a bargain price) since these are designed for
similar service only with more frequent deep discharge cycles in mind.
In this case, a Raspberry Pi with a low power demand, the ideal
battery voltage is 2.3v (float) i.e a single lead acid cell. A
constant volt charger can guarantee that all the cells are getting the
right voltage (there's only the one cell to worry about and any
additional cells wired in parallel will also enjoy this benefit).
You do need a high efficiency low input voltage converter to generate
the required 5 volt supply in this setup but if it avoids the
conditions that would otherwise accelerate corrosion due to cell
voltage imbalance issues common to 6 and 12 volt lead acid batteries,
it will simplify battery care (only the one cell to check voltage (and
keep topped up if it's an open cell type)).
What you lose in voltage, you simply make up in ampere hours to get
the same watt hour capacity. One bonus of packing all your watt hour
requirements into a single cell is that it will either occupy slightly
less space than the equivilent in a 6 or 12 volt battery or allow you
to gain a larger watt hour rating out of the same volume (but slightly
heavier) battery with this gain being greater over the 12 volt battery
than over the 6 volt battery options.
In this case, it's worth giving the single cell SLA option serious
consideration, after all, you're going to need a 5v switching
converter in the mix anyway so why not make it an up converter?
The only remaining problem lies with obtaining a high efficiency
single cell mains charger. The standard shotcky rectifier diodes used
on 5 volt supplies represent a 10% loss of efficiency all on their own
from their typical 450 to 500mV forward volt drops when used in the
classic bi-phase fullwave rectifier mode at full rated output current.
The only way to eliminate such losses in a 2.3v charging supply would
be the use of power FETs in an active rectifier circuit. In theory,
reducing the volt drop to 100mV or less, depending on output current
and the choice of and number of FETs used. Such extra complication
will no doubt increase manufacturing costs and hence price _and_
availability. I've no doubt that the benefit of large scale
manufacturing will reduce the premium to just a few percent but that
pre-supposes a high market demand.
More realistically, a compromise on this 'ideal' would be to choose a
14AH 6v SLA over a 7A 12v SLA. They should both cost about the same
(same materials and manufacturing costs in either case, ignoring
disparities in market demand between these two options). Fewer
permutations by which cell voltage imbalance can start the cascade of
overcharging each cell in turn assuming you don't employ them as part
of a higher voltage string.
Perhaps a better version of the 6 volt SLA, where portability is not
a concern, would be to make up the 6 volt battery using seperate
cells. This neatly solves both the inexpensive high efficiency charger
and voltage converter issues and allows monitoring of the individual
cell voltages or, better yet, provision of a voltage sensitive shunt
module across each cell to save healthy cells from the effect of
being overvolted by other less considerate cells dropping in voltage
to due a slightly higher self discharge effect.
Such voltage shunt modules will, naturally include an indicator to
show excessive shunt current demand so you can deal with the real
culprit in a more timely fashion.
HTH
--
J B Good