Gary Mackey National Sales Manager Associated Equipment Corporation

Gary Mackey National Sales Manager Associated Equipment Corporation gary.mackey@associatedequip.com

Gale Kimbrough Engineering & Tech Services Manager Interstate Batteries Gale.Kimbrough@IBSA.com

Paul Lacroix Account Manager Aftermarket MIDTRONICS Corporation placroix@midtronics.com

Daniel C. Cox Technical Support Manager MIDTRONICS Corporation dcox@midtronics.com

AGM Batteries First Use in Vehicles: 1999 First seen in the 1999 Corvette Followed quickly by the 2000 Toyota Prius AGM Batteries are mainstream in many OEM vehicles (cars and trucks) since 2007

AGM Batteries in Vehicles Today Literally every vehicle manufacturer is using AGM batteries in some, if not all, of their models including: GM, Ford, Chrysler/Jeep, Toyota, BMW, Mercedes, etc. Over 24 million vehicles in North America today have an AGM battery The AGM battery population is growing at a rate of over 8 million batteries per year!

As vehicles become more heavily equipped with electronic devices such as: Navigation Premium stereos Steer by wire, Electric AC compressors Stability control Throttle by wire Electric parking brakes Power steering pumps AGM batteries are being employed to provide better electrical reliability compared with flooded lead acid batteries

What are AGM Batteries? AGM = Absorbent Glass Mat AGM batteries have various names Valve Regulated Lead Acid (VRLA) Sealed Lead Acid (SLA) Recombinant Chemistry

SLA Recombinant Chemistry VRLA Gel AGM Multiple names one umbrella

How is an AGM different from Flooded Lead Acid? Manufactured with highly absorbent* AGM separator material (*99.99%) Recombinant chemistry Oxygen recombined through separator between Negative and Positive plates Elements highly compressed Self discharge reduced No shipping restrictions (including air transport) Vibration resistance 10x 20x greater than Flooded Lead Acid (FLA)

AGM (Oxygen Recombination) Process Pos. AGM Neg. AGM batteries have one way pressure relief valves No external gassing unless severely overheated/overcharged Therefore a VRLA battery

AGM Inherent Differences Vs Flooded Lead Acid Batteries Design Feature Impact on Performance More Uniform Compression Better Vibration Tolerance Higher Degree of Compression Longer Cycle Life Higher Purity Materials Longer Shelf Life No Free Electrolyte Less Spill Hazard Lower Internal Resistance & More Surface Area Better Recharge Capability More Power

AGM vs. Gel How are they different? Gel Batteries: Utilize gelled liquid electrolyte (through addition of silicates) Do not provide high cranking power due to reduced active material area Primarily utilized for deep cycle applications Charging voltage limitations Typically 13.8v 14. 1v @ 77F (results in longer recharge times)

Charge Voltage Regulation Recommendations based on variations in temperature Gel 13.8v 13.9v 14.0v 14.1v 14.2v 14.3v 14.4v 14.5v 14.6v 14.7v 14.8v 14.9v Battery Temperatures: Charge Voltage AGM Typically, the midrange Voltage Regulation is based on 77F (25C). As the temperature decreases, the EMF (Electromotive Force=Voltage) should increase. Contact the battery manufacturer for specific information regarding a battery charge profile.

AGM Battery Designs (Absorbed Glass Mat) Conventional Type Spiral Type

AGM Batteries (2 distinct plate material types) Type 1 Positive grids pure or virgin lead Internal resistance lower than AGM Type 2 or Flooded Increased deep cycle ability @ (3X @ 75 DOD Type 2) Greater recharge ability (1.5X Type 2 ) Type 2 Positive grids recycled /alloyed lead Higher internal resistance than Type 1 Much lower Internal resistance than Flooded Improved charge acceptance over Flooded

Where do the OEs use AGM Batteries? 12v battery for (most) High Voltage Hybrid vehicles 12v battery for all Stop Start technology vehicles 12v battery for all Full Electric vehicles Optional battery for virtually all high end luxury vehicles

High Voltage Hybrid Applications Why AGM? Space / Location Running out of space in engine compartment Remote location requires AGM for safety (Ventilation of hydrogen and oxygen gases) During electric mode operation (typically short trips and low speed driving) regenerative charging system supplies both HV and 12v systems. More robust 12v battery required. Recharge ability (2X 3X faster than flooded) Increased cycle ability (especially Type 1) Increased # of starts per cycle (2X 3X over flooded)

Stop Start Applications Why AGM? Recharge ability (2X 3X faster than flooded) Increased cycle ability (especially Type 1) Increased # of starts per cycle (2X 3X over flooded) Higher voltage retention under load Can be mounted in almost any position; therefore can be located very close to starting mechanism

OTHER Applications Why AGM? Sophisticated electrical systems / devices require slightly higher voltage Even 2 3 /10ths of a volt can make a difference

Replacement Applications Why AGM? Why not (cheaper) FLA? Charging system control module software is different FLA batteries will show higher internal resistance Re Flashing of module required if FLA installed Battery (on vehicle) software registration may be required on some models

AGM Battery Testing (Including Diagnostic Charge Testing) AGM batteries require an AGM specific testing algorithm for accurate decisions and results Lower internal resistance and higher conductance Same algorithms for Flat plate Type 1 and 2 testing Different algorithms for Flat plate and Spiral testing Same chemistry; different design structures

Battery Testing Challenges Locating the battery in the vehicle Proper identification of battery type Even with a visible battery, identification is difficult FLA, AGM (Spiral or Flat plate) or Gel Obtaining a good, clean connection to the terminals Incorrect user inputs (Rating system / Rating value ) = inaccurate test results Blame the Battery syndrome Starting/charging system or wiring issues can be the root cause of No Starts

Regular FLA AGM Spiral

AGM Spiral AGM Motorcycle

Group 31 AGM Flat plate Type1 Group 31 Gel battery

The Need for abattery Guide The Battery Council International (BCI) Battery Replacement Data Book lists vehicle applications originally equipped with an AGM battery BCI guides denotes AGM as (VRLA) Look for footnote #47 in the current version BCI guide Also denotes use of Gel cells Primarily reserve battery; Typically not cranking battery

The Need for a Battery Guide Batteries in today s vehicles are often mounted under the front or back seat, or even in the trunk, often under the spare tire Battery guides provides battery access and service location info for vehicles Battery guides also provides battery disconnect procedures to prevent loss of pre sets such as clock, radio stations, electric seats, and drivability computers

Battery Installation Challenges Educating the customer on the correct battery chemistry, type, size, rating, etc. AGM batteries are generally more expensive, but are OE specified/installed for many applications Protecting on board computer memory Loss of pre sets (Driver selected) Engine/Transmission performance relearn Steering Angle sensor setting loss Security system lockout (Radio) Security system lockout (Ignition disable) OBD Battery Registration (Where required)

AGM Battery Special Care and Maintenance NEVER charge an AGM (or a Gel cell battery) with a conventional battery charger Even automatic chargers will output 16 18 volts (necessary for flooded lead acid batteries) will damage AGM s Only charge these type of batteries with voltagecontrolled chargers AGM should never be charged at higher than 14.4 Volts (unless a diagnostic charger / tester with AGM specific algorithms monitoring amps, volts and battery temperature is utilized)

AGM Battery Special Care and Maintenance Risks of improperly charging AGM s includes: Damage to the battery within minutes of improper charging Immediate failure or Walking Wounded Risk of explosion Potential damage to the vehicle (including interiors, depending on battery location) from battery explosion

Is Your Shop Missing Some Pieces to the Puzzle? In today s vehicles, new battery technology has changed the way we need to service the vehicle s electrical systems. Are you charging new battery technologies properly? AGM battery charging voltage needs to be monitored and controlled Improper charging can damaged AGM batteries very quickly

AGM Battery Charging Equipment Facilities With Charging Equipment for AGM Batteries % Yes: By Type of Facility 100% 50% 0% 35% 79% 50% 32% Overall Dealer Franchise Independent Repair Facilities With Charging Equipment for AGM Batteries % Yes: By # of Technicians 100% 50% 35% 21% 36% 39% 64% Survey March 20112 0% Overall 0 to 1 2 to 3 4 to 10 10 or More

Gang charging AGM Batteries Charge 1 10 batteries Lower warranty exposure Batteries lose 5% state of charge every month just sitting on the shelf Keep battery inventory from sulfating by charging every 60 days or when OCV drops to 12.5V or less

Takeaways Vehicles OE equipped with AGM batteries are a significant percentage of the vehicles going through your service bays every day and growing AGM batteries are referred to by a number of different names VRLA, SLA, Recombinate Chemistry etc. AGM batteries are of either flat plate or spiral design Advantages of AGM batteries over FLA are fueling their increased usage Gel Cell batteries are NOT AGM

Takeaways 12 volt batteries in HV Hybrids, Stop Start and Full Electric vehicles are (virtually) all AGM OE Installed AGM batteries must be replaced with AGM batteries; Installing a FLA in an application that requires an AGM will result in a shorter battery life. Accurate testing requires specific flat plate and spiral AGM algorithms Identifying proper battery type, design and rating is critical; Which is challenging both in and out of the vehicle BCI Replacement Data Book and aftermarket guides are helpful tools

Takeaways Protecting on board computer memory is important before disconnecting a battery; Avoids need to perform resets or driving vehicle to relearn OBD battery registration is required on some vehicles when replacing the battery Never charge an AGM battery at over 14.4 volts unless a diagnostic charger / tester with AGM specific algorithms that monitors amps, voltage and battery temperature is utilized Improper charging is hazardous, can damage the battery or shorten battery life

Takeaways For charging purposes: When in doubt, treat the battery as if were an AGM to help eliminate the dangers associated with overcharging

Thank You! Questions & Answers