XX Brigade Combat Team
AGM / VRLA Battery Management, Testing and Charging SOP
1. Purpose. This Standard Operating Procedure (SOP) outlines the requirements for the proper recharging,
storage and turn-in of Lead Acid flooded, GEL, and AGM / VRLA batteries used in military vehicles and
equipment of the XX Brigade Combat Team (BCT).
2. Scope. Provisions of this SOP are applicable to the XX BCT personnel and operations within U.S. Army
Garrison, Fort Carson.
3. Objectives.
a. Reduce battery consumption and procurement cost by recovering (recharging) vs replacing all battery
types.
b. Reduce the incidences of premature battery disposal, extend battery performance and achieve cost
savings to the Unit.
c.
Establish a standard procedure for battery management in order to maintain all assigned equipment at a fully
mission capable status.
4. References.
a. AR 750-1, Army Materiel Maintenance Policy, 20 Sep 07.
b. DA Pam 750-8, The Army Maintenance Management System (TAMMS) Users Manual, 22 Aug 05.
c.
TB 9-6140-252-13, Recharging Procedures For Automotive Valve Regulated Lead-Acid Batteries, 22 Sep
2011.
d. TB 43-0134, Battery Disposition and Disposal, 19 May 2008.
e. TM 9-6140-200-13, Automotive Lead-Acid Storage Batteries, 26 May 2011.
f.
Individual Lead-Acid battery Material Safety Data Sheets (MSDS).
g. EPA Standards for Universal Waste Management, 40 CFR part 273.
h. OSHA Standards (29 CFR 1910.178(g)(1-12); 29-CFR 1910.305(j)(7)); 29 CFR 1910.132.
5. Management Program.
a. Personnel will use batteries prescribed by the equipment technical manual, or authorized substitutes IAW
higher level guidance. Maintenance free, AGM/VRLA type batteries, should be used whenever possible
and Chain of Command directed to enhance readiness and reduce the BCT logistics and environmental
footprints.
b. Testing and recovery of all batteries will be attempted and documented before discarding.
c.
Unrecoverable (used) batteries will be labeled IAW local requirements. Most used batteries are
considered “UNIVERSAL WASTE” as defined in 40 CFR part 273. Any battery with a broken casing may
be considered “HAZARDOUS WASTE”. The DPW Environmental Division Compliance Inspections
Program should be contacted for guidance on the proper management of broken batteries.
d. The BCT SSA should not accept batteries unless red tagged with a DD Form 1577. Used batteries
waiting disposition should be in an area marked as, “Used Batteries”, as stipulated in 40 CFR 273.14.
e. All battery maintenance, testing, charging, servicing and replacements will be performed IAW this SOP,
TM 9-6140-200-13, TB 9-6140-252-13 and OSHA Standards (29 CFR 1910.178(g)(1-12); 29-CFR
1910.305(j)(7)); 29 CFR 1910.132 and any other applicable safety guidelines.
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XX Brigade Combat Team
AGM / VRLA Battery Management, Testing and Charging SOP
f.
Mission permitting, battery inspections, conductance/diagnostic tests, servicing and charging will
be accomplished in the vehicle or platform while the batteries are still mounted on the equipment.
This always saves time and money to recover batteries on the platform when possible. It should be noted
that the majority of physical damage to batteries occurs during removal, installation and transportation.
For that reason, every attempt will be made to service the “depleted” batteries in place on the
platform before removing from the equipment.
g. Refer to Appendix 1 - Battery testing and charging diagram flow.
6. Battery Description.
a. There are a considerable number of different types of batteries in use across a wide variety of platforms.
b. For Gel and Flooded lead acid battery maintenance please refer to TM 9-6140-200-13. Flooded (wet)
batteries have a large reservoir of electrolyte surrounding the battery plates. Each cell must be serviced
separately.
c.
Absorbed Glass Mat (AGM)/Valve-Regulated Lead-Acid (VRLA) batteries are lead-acid batteries in which
the electrolyte is held in thin fiberglass mats that are sandwiched between the battery plates. AGM/VRLA
batteries have only a very small amount of electrolytes. Due to the nature of this construction, the battery
is sealed and may be classified as Non-Spillable or Maintenance Free. Check individual MSDS for battery
classification. Each cell has a vent cap to allow the battery to vent any gases that are generated internally.
These vent caps are non-removable and should never be tampered with.
d. AGM/VRLA type batteries do not require maintenance beyond recharging and periodic cleaning IAW MCS
requirements.
e. AGM/VRLA batteries are non-spillable. They will not leak or spill even if tipped over or accidentally
cracked. These batteries will also work temporarily after cracked open or after taking a round.
f.
AGM/VRLA batteries have a shelf life that is longer than traditional flooded lead-acid batteries. This type
of battery can also be held in storage for an extended period of time and still have the power to perform
many operational functions without having a charge applied before being placed into service. However,
batteries should always be tested before being placed into service. This will significantly increase the life
expectancy of the battery and improve overall performance. A general rule of thumb is that any new lead
acid 12V battery that is below 12.6Vdc should be charged prior to installation.
g. AGM/VRLA batteries have proven to be highly recoverable. They can be fully recharged, multiple times,
from a completely discharged (dead) state. This is especially true with the higher quality pure lead/tin
battery plate types, such as all Optima batteries, 6TAGM Hawker, and 24Vdc Teledyne.
h. Hawker, Batcore, and Exide 6TAGM/VRLA batteries are authorized as a direct replacement to the
conventional 6TMF and 6TL flooded (“wet”) cell lead-acid batteries used in tactical or combat vehicles.
i.
Optima and 24 Volts Direct Current (VDC) Concorde or Teledyne AGM/VRLA type batteries are
authorized for use in 3KW through 200KW generators.
j.
Optima batteries are also authorized to be used on most types of support equipment, such as fork lifts,
ECUs, pumps, fuel and waters systems, light sets, etc.
k.
Refer to Appendix 2 for Examples of Common Lead Acid Batteries and National Stock Numbers
(NSNs).
7. Testing, Charging and Maintenance Equipment.
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XX Brigade Combat Team
AGM / VRLA Battery Management, Testing and Charging SOP
a. PulseTech 490 series battery analyzers or similar devices are recommended for testing the batteries.
These are conductance testers and are standard on each SATS, and FRS. It is recommended that
mechanics who routinely conduct vehicle services, or support unit PMCS be issued a tester with their
general mechanics tool kit.
b. AGM/VRLA batteries need a high quality charger. The charger should be an automatic type as to not
accidentally overcharge the battery if it is left connected. Constant current chargers are not recommended
for charging AGM/VRLA batteries. A pulse charger (smart charger) must be use instead, as the entire
charge process is controlled by microrocessors.
c.
A battery maintenance charge system should be used to keep batteries that are stored for an extended
period of time from sulfating and in a fully charged state. Once a battery is taken off a charger it will
immediately start to discharge. Battery Maintainers help to mitigate an idle batteries discharge rate and
will extend a batteries useful life.
d. Refer to Appendix 3 for examples of battery testing, charging and maintenance equipment with
corresponding NSNs.
8. Responsibilities.
a. Officer in Charge.
(1) Appoints on orders (Appendix 4) enough battery management and maintenance personnel to oversee the
daily operation of the Company, BN or BDE consolidated battery maintenance areas. Each CO or BN may
have a smaller consolidated battery maintenance area, and Maintenance Leadership assigned to these
units will be responsible for their operations.
(2) Ensures assigned personnel are competent on the basis of appropriate education, training, and/or
experience to perform their assigned duties. Arranges training for newly assigned personnel within 30 days
of assignment.
(3) Ensures necessary equipment, supplies and publications are identified and available to assigned
personnel. This includes, but is not limited to, proper battery maintenance/charging equipment,
appropriate personal protective equipment (PPE), spill equipment, technical manuals/bulletins and policy
memorandums.
(4) Assumes overall responsibilities for compliance with instructions and procedures established for the BDE
consolidated battery maintenance area.
b. Vehicle Maintenance Supervisory Personnel.
(1) Ensures that batteries are serviced during scheduled maintenance. Batteries should be tested and fully
charged on the vehicle during S and A services. If batteries are out of balance appropriate actions should
be taken. See Appendix 1.
(2) If determined necessary to remove batteries from platform (failure to charge, or mission requirements),
ensure batteries are taken to the unit consolidated battery maintenance area for exchange. Unit
consolidated battery maintenance area personnel will make every attempt to charge IAW their available
charging assets and available time requirements. The unit shop supply should stock a small amount of
batteries to be used as 1 for 1 exchange when required. This will help reduce down time, as some
batteries can take several days on a charger prior to being completely recharged.
(3) Use batteries prescribed by the equipment technical manual or as authorized from higher. If directed to
begin using AGM / VRLA batteries it will be accomplished thru attrition, as the older batteries fail
and cannot be recovered. The same smart charging systems that are used on the AGM / VRLA batteries
can be used to extend the life of all other types of batteries, which includes flooded lead acid and Gel
batteries.
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XX Brigade Combat Team
AGM / VRLA Battery Management, Testing and Charging SOP
(4) Ensure mechanics apply a charge whenever the Open Circuit Voltage (OCV) is 12.6 VDC or less on new
or reconditioned 12V batteries prior to installation. Recharge batteries to 100% capacity IAW the
manufacture specifications. Leaving batteries in a discharged condition, even a partial discharge, will
cause sulfation on the plates which then reduces battery capacity and leads to premature battery failure.
(5) Unit maintenance personnel will evacuate all batteries they cannot charge to the BDE consolidated battery
maintenance area. BDE consolidated battery maintenance personnel will make every effort available to
recover batteries before determining they are unserviceable.
(6) Ensure all maintenance personnel (and Shop Supply reps as required) are fully trained on proper
procedures for testing, recharging, and maintaining all types of lead acid batteries IAW TM 9-6140-20013, TB 9-6140-252-13, OSHA Regulations (29 CFR 1910.178(g) and 29-CFR 1910.305(j)(7)), and other
applicable safety guidelines. Training assets / info in section 9 of this SOP.
(7) Ensure Shop Supply personnel are tracking and re-issuing replacement batteries to Unit maintenance
personnel, or turning-in “unserviceable/condemned” batteries to the Unit SSA for consolidation.
(8) Ensure all personnel use required PPE, there is adequate ventilation, and spill equipment IAW applicable
safety guidelines.
(9) Maintain a battery recovery log. This can be used to determine cost savings, identify trends, etc.
(10) Ensure Shop Supply personnel keep charged / recovered batteries stored at the battery maintenance
facility, and whenever possible connected to a battery maintainer to prevent sulfating. This will help ensure
the batteries are fully charged before re-issuing, as batteries will discharge when in storage.
(11) Ensure the turn-in of all unserviceable battery types (Flooded, GEL and AGM/VRLA) is completed IAW
unit SSA, and installation requirements. Permanently mark each battery or container, as stipulated in 40
CFR 273.14, with the words “Used Battery”.
(12) Duct tape exposed battery terminals to prevent external short circuiting and stack used batteries on pallets
No more than 2 high.
(13) Ensure unit environmental representative maintains MSDSs for each type of battery stored and managed
within the unit area.
(14) Ensure unit Publication representative maintains current copies (electronic copies are authorized) of all
applicable reference publications, technical bulletins, manuals and policy memorandums on-site.
9. Training.
a. Unit personnel and Battery Maintenance Facility Operators must be adequately trained to perform their
battery management duties as assigned. Annual refresher BMMP training will be conducted at the unit
level. When new personnel are assigned they will be trained on current unit BMMP procedures within 30
days of arrival. Training can be conducted by qualified Warrant Officers or NCOs that have been trained
previously.
(1) Free on-site BMMP training or a copy of the latest training slides can be provided by the PulseTech Field
Support Representatives (FSR). Contact:
Eastern US and USAEUR – Roy Johnson, rjohnson1@twcny.rr.com
Western US and USAPAC – Tom Pigorsh, tom.pigorsh@comcast.net
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XX Brigade Combat Team
AGM / VRLA Battery Management, Testing and Charging SOP
(2) TACOM training videos can be viewed via the Library of TACOM Training Information Site (LOTTIS) at:
https://utap.army.mil. NOTE: Click on the Videos Tab once logged into the site.
10. Safety / Environmental for Battery Charging areas.
a. Off platform battery charging area must be well-ventilated with impervious surfaces and adequate
containment in the event of spills for flooded lead acid batteries. AGM or Non-spillable batteries can be
charged on pallets, but all flooded types must be on secondary containment of some type during off
platform charging operations.
b. Signs prohibiting smoking or the use of open flames, sparks or other devices used as igniting sources will
be displayed at the facility.
c.
Emergency shower must be available, inspected and maintained in good operating condition.
d. Non-combustible dry sweep, absorbent materials and spill control equipment will be kept on hand in the
event of a spill. AGM/VRLA are non-spillable lead-acid batteries, and are not expected to leak or spill.
However, caution must still be exercised when handling this type of battery as they still contain sulfuric
acid / electrolyte in their fiberglass matting. Proper care and considerations should be taken to protect
equipment and personal clothing when handling batteries with damaged or broken cases.
e. 6TAGM/VRLA type batteries weigh 88 pounds. Follow safe lifting and carrying procedures to prevent
back injuries. Batteries should be carried by the casing handles. A two-man lift is recommended.
f.
Remove all jewelry, such as rings, ID tags, watches, and bracelets when charging batteries. If jewelry
contacts a battery terminal, a short can result and may cause injury to personnel and/or damage
equipment.
g. On flooded lead acid batteries, goggles and gloves are required whenever vent caps are opened and
battery is serviced. If batteries fluid is low add distilled water to appropriate level IAW manufacturer
guidance. When adding distilled water a full face shield is recommended. Use baking soda, lime or other
powder to neutralize any buildup of excess sulfuric acid on the outside of the battery if necessary.
h. AGM/VRLA type batteries do not require maintenance beyond recharging. Under no circumstances
should any attempt be made to introduce any substances, e.g. acid, distilled water or alkali to the
battery. Removing dust, dirt or corrosion buildup on the exterior of the battery is recommended for
optimal operation.
i.
Perform all charging functions in a well-ventilated area. The potential for hydrogen gas build up and
explosion exists with any lead-acid battery including AGM/VRLA type batteries.
j.
In the case of AGM/VRLA type batteries, small quantities of hydrogen gases are released from the
battery pressure relief valve during normal charging. Typically, the hydrogen gas dissipates very rapidly
and never reaches a concentration level that is hazardous. However, if the battery is being charge in an
enclosure with minimal airflow, the concentration of hydrogen could build up to a high enough
concentration to be of concern. A torch, match, flame, lighted cigarette, or any spark from metal tools
accidentally contacting the battery terminals, could cause ignition of these gases.
k.
Immediately stop charging any battery that develops signs of melting, swelling or if the surface
temperature of the case is too hot to comfortably touch with a bare hand. Do not handle or attempt to
move the battery until it has cooled for a couple hours to avoid the risk of an explosion.
l.
Refer to the battery MSDS for additional safety precautions and handling instructions.
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XX Brigade Combat Team
AGM / VRLA Battery Management, Testing and Charging SOP
m. Report any safety incidents to the officer in charge and in accordance with your Unit’s specific safety
procedure.
a. Pre-Charge Battery Inspection.
(1) Perform a visual inspection before starting to test or recover any battery. Batteries with physical
damage described below should be turn-in for reclamation/recycling.
(2) Permanently mark each damaged AGM/VRLA battery casing with the words “Used Battery” and
with the date the battery was determined to be unusable.
(3) Attach a red unserviceable (condemned) tag, DD Form 1577, to the battery before turning-in to the
SSA.
(4) Things to look for consist of the following:
 Check top, sides, and bottom for cracks, dents, leaking or swelling in the battery case and lid.
 Check that battery lid and case is sealed.
 Make sure terminals are not melted, bent, or otherwise damaged.
 Check that the battery is not missing cell vent caps. Do not attempt to replace missing vents.
 Check that all vent caps are in place (flush) and do not appear to be elevated. Elevated vent caps
are a sign of a defective vent or that the battery has gassed excessively. Gently tap vent back in
place, then with a permanent marker, mark the vent with an “R”. If it elevates again during charging
or operational use, dispose of battery.
 If a battery is turned in for recharge and a vent cap with an “R” marked on it is elevated again,
disposal is authorized without further testing. Label battery as “Damaged” and attach a red DD
Form 1577 tag and DA Form 2404.
b. Pre-Charge Battery Testing.
(1) After performing the visual inspection, and if required use a battery post cleaner or wire brush to
clean any corrosion build-up from the terminals / battery posts.
(3) Perform conductance testing with a diagnostic tester equipped with a digital read-out. The digital
display will provide the state of health of the battery; Cold Cranking Amps (CCA) and OCV; the
display will also indicate whether the battery needs to be recharged and re-tested or if the battery has
a bad cell. If no internal damage is indicated on the digital display, proceed with charging procedure.
(4) Sort batteries according to State of Charge (SOC)/OCV. To increase recovery rate and turnaround
time, efforts should focus on recharging the highly recoverable batteries, requiring the least amount of
charge time, first.
(5) PulseTech 490 series battery analyzers or similar devices are recommended for testing the batteries.
c. Battery Charging.
(1) Charger should be automatic types as to not accidentally overcharge the battery if it is left connected.
Approved chargers are listing in the TM, TB and in Appendix 3 of this SOP.
(2) Charge the battery according to the diagnosis displayed on the analyzer and by following the charger
manufacturer’s recommendation for charging rates, settings and connections. Connect batteries to
the charger, ensuring clamp wiring and contacts are tight, clean and free of corrosion to assure good
connections. See Appendix 1.
(3) 6TAGM/VRLA batteries are fully charged at 12.9 OCV. Charging is recommended when the OCV is
12.7 or less. For optimum battery performance and life expectancy, discharge levels should not be
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XX Brigade Combat Team
AGM / VRLA Battery Management, Testing and Charging SOP
allowed to fall below 50% or 12.2 OCV. The batteries will be recharged to 100% capacity or as close
to 12.9 OCV as the battery is capable of achieving.
(4) Examine batteries periodically during the charging cycle. Charge batteries for 48 hours. Night and
weekend charging of batteries should be performed with the pallet or bench top chargers only. The
ProHD charger should not be left on at night or weekends while personnel are not present.
(5) Severely depleted batteries can take up to three days or even longer to recharge.
(6) Batteries are recovered when charge current (amp meter on charger) drops to less than 1 amp per
battery and holds there for 3 hours. Automatic chargers will stop charging and give a screen reading
of “Charge Complete” and/or completion light.
d. Battery Resting Period.
(1) After completing the charge, disconnect the charger, wait 30 minutes and test the battery. Then rest it
for 24 hours before retesting if mission allows. This is because batteries that are still heated from
charging process may give erroneous readings.
e. Post Charge.
(1) After the resting period, test the battery charge and health according to TB 9-6140-252-13.
(2) The charging cycle may need to be repeated to ensure full recharge of the battery. Refer to TB 96140-252-13 and Appendix 1 of this SOP for additional instructions.
(3) Determine if the battery is fit for reissue, stocking or classified as unserviceable thereby requiring
turn-in to the Unit SSA.
(4) Tag the battery according to its condition code.
 Yellow tag (DD Form 1574) for serviceable batteries if unit required. Battery is good for reuse or
place on shop stock.
 Red tag (DD Form 1577) battery is damaged or not recoverable after three (3) days of attempting to
charge. Permanently mark each AGM/VRLA battery casing with the words “Used Battery” and
with the date the battery was determined to be unrecoverable.
(5)
Keep AGM/VRLA batteries stored at the battery maintenance facility, connected to the battery
maintainer (Appendix 3) to prevent sulfating and to ensure the batteries are fully charged before reissuing. The SSA may require several of these to maintain batteries waiting to be issued to units.
(6) Depending on the length of time held in storage, a top-off charge may need to be applied before
placing the battery into service.
10. POC for this SOP is the undersigned at 123-4567.
James Smith
MAJ, LG
BDE SPO
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