Description
Overview of Industrial Wireless Replacement Batteries
Industrial Wireless Replacement Batteries rated at 3.6 volts and 19,000 milliamp-hours are essential for powering wireless devices in rugged environments. These batteries are known for their long life, high performance, and stability in extreme conditions. Commonly based on Lithium Thionyl Chloride chemistry, they power devices such as sensors, meters, and transmitters used in industries like oil and gas, manufacturing, utilities, and automation.
Chemistry and Specifications
These batteries use Lithium Thionyl Chloride, which provides much higher energy density than alkaline or lithium-ion alternatives. They deliver a consistent 3.6 volts, with a termination voltage around 2.0 volts. With a capacity of 19,000 milliamp-hours, they support long-term device operation with minimal maintenance.
Physically, these D-sized batteries measure about 34.5 x 61.5 mm and weigh 100–110 grams. They also feature a low self-discharge rate—less than 1% per year at room temperature—which allows them to last 10 to 20 years in storage.
Designed for Tough Conditions
One standout feature is their ability to operate in extreme temperatures. They work reliably from -55°C to +85°C, making them ideal for use in cold pipelines or hot desert installations. Their rugged design resists shock, vibration, and humidity, which are common in industrial environments. Storing them below 30°C further extends their life.
Key Applications
These batteries are perfect for wireless industrial instrumentation that demands low power and long lifespan. Examples include:
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Wireless sensors that track temperature, pressure, flow, or vibration.
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Telemetry systems that monitor pipelines or environmental conditions in remote areas.
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Smart meters for gas, water, or electricity that transmit data for years without needing replacement.
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Automation systems such as door sensors, asset trackers, and backup power for clocks or emergency transmitters.
Benefits for Wireless Systems
The biggest advantage is their long operational lifespan—anywhere from 3 to 20 years, depending on the application. This reduces both maintenance costs and system downtime. Their compact size fits tight spaces without compromising performance. Also, their stable voltage and low self-discharge rate make them ideal for backup systems or infrequently used devices.
Unlike consumer-grade batteries, they maintain performance even in extreme weather, making them far more dependable.
Limitations and Considerations
Despite their strengths, these batteries do have limitations. They are non-rechargeable and must be replaced after use. Recharging them is unsafe and can cause fire or explosion. Their low continuous discharge rate—under 200 milliamps—means they are not suitable for high-drain devices.
Additionally, they can experience passivation. This is a temporary drop in voltage after long storage, caused by a protective film on the lithium. Fortunately, it can be fixed by briefly discharging the battery. Compatibility is also key. Their 3.6-volt output is much higher than 1.5-volt alkaline cells, so they can damage unsupported devices.
Best Practices for Handling
To get the best performance, store these batteries in a cool, dry, and well-ventilated area. Always check the open-circuit voltage (at least 3.6V) and load voltage (around 3.2V) before use. In multi-battery setups, replace all batteries at once to avoid inconsistencies.
Deploy the batteries within a few months of purchase to avoid passivation issues. Follow strict safety practices—never short-circuit, crush, or expose them to heat above 100°C. If you need custom configurations, solder with care or use professional methods to avoid damage.
Conclusion
Industrial Wireless Replacement Batteries with 3.6V and 19,000mAh ratings are a smart choice for demanding applications. They combine longevity, reliability, and durability in extreme conditions. Though they’re best for low-power, non-rechargeable systems, their benefits far outweigh their limitations. With proper use and care, they ensure uninterrupted operation for critical wireless systems.
Also check out, “Industrial Instrumentation“
Specifications
Wireless batteries with specifications of 3.6V and 19,000mAh (19Ah) are typically Lithium Thionyl Chloride (Li-SOCl₂) primary (non-rechargeable) batteries, commonly used in industrial instrumentation due to their high energy density, long lifespan, and reliability in harsh environments. Below is a detailed description of these batteries and their use in wireless industrial instrumentation:
Key Characteristics of 3.6V, 19,000mAh Batteries
Chemistry
Lithium Thionyl Chloride (Li-SOCl₂) is the primary chemistry for these batteries. This chemistry provides high energy density (up to three times that of alkaline batteries) and a stable voltage output.
Non-rechargeable, designed for long-term, low-power applications.
Voltage
Nominal voltage of 3.6V, with a termination voltage around 2.0V.
Higher than standard 1.5V alkaline D cells, making them unsuitable for devices designed for lower voltages.
19,000mAh (19Ah), providing significant energy storage for extended operation without frequent replacement.
Actual capacity may vary depending on discharge rate; these batteries perform best at low currents (e.g., <200mA).
Size and Form Factor
Typically, D size (ER34615 or equivalent), with dimensions around 34.5mm x 61.5mm (1.3″ x 2.42″).
Weight is approximately 100-110g (3.77 oz).
Operates effectively from -55°C to +85°C (-76°F to +185°F), ideal for harsh industrial environments.
Can be stored at Temperatures below 30C to maintain Shelf Life
Shelf Life
Ultra-low self-discharge rate (<1% per year at 68°F), enabling a shelf life of 10-20 years under proper storage conditions.
Safety and Certifications
Non-flammable electrolyte and UL-recognized (e.g., BBCV2.MH48285).
Passed UN transportation tests (T1-T8).
Passivation can occur (a temporary voltage drops after long storage), requiring brief discharge to activate.
Installation
Installation Procedures for 3.6V, 19,000mAh Wireless Lithium Batteries in Industrial Instrumentation
Preparation and Safety Precautions
Begin by gathering all necessary tools and materials, including the 3.6V, 19,000mAh Lithium Thionyl Chloride battery, the industrial instrumentation device, a compatible battery holder or connector, a multimeter, insulated gloves, and a clean, static-free workspace. Verify that the device is powered off and disconnected from any external power source to prevent electrical hazards. Wear insulated gloves to protect against accidental short-circuiting, as these batteries can pose fire or explosion risks if mishandled. Ensure the workspace is well-ventilated, dry, and free of flammable materials, maintaining a temperature below 30°C to preserve battery integrity. Review the device’s manual to confirm compatibility with a 3.6V battery, as using an incompatible voltage could damage the equipment.
Battery Inspection and Testing
Examine the battery for physical damage, such as dents, leaks, or corrosion, which could indicate a defective unit. Discard any damaged batteries according to local hazardous waste regulations. Use a multimeter set to DC voltage mode to measure the battery’s open-circuit voltage, which should read at least 3.6 volts. If the voltage is significantly lower, the battery may be defective or passivated due to long storage. To address passivation, connect the battery briefly to a low-current load, such as a 100mA resistor, for a few minutes, then retest the voltage. A healthy battery should stabilize at or above 3.2 volts under load. If the battery fails to meet these thresholds, replace it with a new unit to ensure reliable performance.
Accessing the Battery Compartment
Locate the battery compartment on the industrial instrumentation device, typically found on the back or underside, secured by a cover or panel. Refer to the device manual for specific instructions on accessing the compartment, as some units may require a screwdriver or specialized tool to remove the cover. Gently open the compartment, taking care not to damage any internal wiring or components. Inspect the compartment for dust, debris, or corrosion, cleaning it with a dry, lint-free cloth if necessary. Ensure the battery terminals or holder inside the compartment are intact and free of oxidation, as poor connections can impair device performance.
Battery Installation
Orient the battery according to the polarity markings in the compartment, typically indicated by plus and minus symbols. Insert the battery carefully, ensuring the positive and negative terminals align with the corresponding contacts in the holder. If the device uses a connector or wire leads, securely attach the battery terminals, double-checking the connection to prevent loose or reversed polarity, which could damage the device or battery. For devices requiring multiple batteries, install all batteries simultaneously to avoid mixing old and new cells, which can reduce overall lifespan. Press the battery firmly into place, ensuring it is seated securely without forcing it, as excessive pressure could damage the terminals or compartment.
Securing the Compartment
Close the battery compartment cover, ensuring it snaps into place or is securely fastened with screws, depending on the device’s design. Verify that the cover is properly sealed to protect against environmental factors like dust or moisture, which are common in industrial settings. If the device is rated for outdoor or harsh environments, confirm that any gaskets or seals on the compartment are intact to maintain its ingress protection rating. Gently shake the device to ensure the battery does not move inside, as a loose battery could cause intermittent power loss.
Device Testing and Activation
Power on the device according to its operating instructions, observing any indicator lights or display to confirm it is functioning correctly. If the device includes a diagnostic mode, activate it to verify battery status and ensure proper voltage delivery. Monitor the device for a few minutes to detect any issues, such as flickering displays or error messages, which could indicate a faulty connection or incompatible battery. If the device fails to operate, power it in off, recheck the battery installation, and retest the battery voltage. For wireless instrumentation, confirm that the device successfully transmits data to its receiver or network, as this verifies both power and functionality.
Final Checks and Documentation
Perform a final inspection of the installation, ensuring the battery compartment is secure and the device is properly mounted in its operational environment. Record the installation date and battery specifications in the device’s maintenance log, as this helps track replacement schedules, typically every 3 to 20 years depending on usage. If the device is part of a larger system, notify the system administrator or maintenance team of the battery installation to update records. Dispose of any packaging or old batteries in compliance with local regulations, as Lithium Thionyl Chloride batteries require special handling due to their hazardous materials.
Environmental and Safety Reminders
Place the device in its intended industrial environment, ensuring it operates within the battery’s temperature range of -55°C to +85°C. Avoid exposing the battery to temperatures above 100°C, crushing, or short-circuiting, as these can lead to fire or explosion. If soldering is required for custom configurations, consult a professional to avoid damaging the battery. Regularly inspect the device during routine maintenance to ensure the battery continues to perform reliably, replacing it proactively based on our recommended lifespan or if performance degrades.
Maintenance
Maintenance Procedures for 3.6V, 19,000mAh Wireless Lithium Batteries in Industrial Instrumentation
Initial Setup and Documentation
Begin maintenance by establishing a comprehensive record-keeping system for each industrial instrumentation device powered by a 3.6V, 19,000mAh Lithium Thionyl Chloride battery. Document the installation date, battery brand, model (e.g., PKCELL ER34615 or Tadiran TL-5930), and the device’s operational environment, including temperature and humidity conditions. Note the manufacturer’s recommended battery lifespan, typically 3 to 20 years depending on usage, to schedule proactive replacements. Create a maintenance log to track inspection dates, battery performance metrics, and any observed issues. Ensure all maintenance personnel are trained on the handling of Lithium Thionyl Chloride batteries, emphasizing their non-rechargeable nature and risks of fire or explosion if mishandled.
Routine Visual Inspection
Conduct visual inspections of the instrumentation device every six months or per the manufacturer’s guidelines, focusing on the battery compartment and surrounding areas. Power off the device and disconnect it from any external power source to ensure safety. Open the battery compartment using the appropriate tools, such as a screwdriver, as specified in the device manual. Examine the battery for signs of physical damage, including dents, swelling, leaks, or corrosion, which could indicate a compromised unit. Inspect the compartment’s terminals and connectors for oxidation, dust, or debris, cleaning them gently with a dry, lint-free cloth if necessary. Verify that the battery is securely seated and that the compartment cover remains properly sealed to maintain environmental protection, especially in harsh industrial settings.
Battery Performance Testing
Test the battery’s performance during each maintenance cycle using a multimeter set to DC voltage mode. Measure the open-circuit voltage, which should be at least 3.6 volts for a healthy battery. If the voltage is below 3.2 volts, the battery may be nearing the end of its life or suffering from passivation due to prolonged inactivity. To address passivation, apply a brief low-current load, such as a 100mA resistor, for a few minutes, then remeasure the voltage, which should stabilize above 3.2 volts under load. If the device supports diagnostic functions, activate them to check the battery’s remaining capacity or health status. For wireless instrumentation, confirm that the device maintains consistent data transmission to its receiver or network, as power fluctuations can disrupt connectivity. Record all voltage readings and diagnostic results in the maintenance log for trend analysis.
Environmental Condition Monitoring
Assess the device’s operating environment during each maintenance check to ensure it remains within the battery’s operational range of -55°C to +85°C. Use a thermometer or environmental sensor to verify ambient conditions, particularly in extreme settings like oil refineries or arctic installations. Check for exposure to excessive humidity, dust, or vibration, which could compromise the battery or device performance. If the device is outdoors, inspect the battery compartment’s seals and gaskets to confirm they prevent moisture ingress. Address any environmental issues, such as relocating the device or adding protective enclosures, to maintain optimal battery function. Avoid storing spare batteries in conditions exceeding 30°C, as higher temperatures accelerate self-discharge and reduce shelf life.
Battery Replacement Protocol
Replace the battery proactively based on the manufacturer’s recommended lifespan or if performance tests indicate a voltage drop below 3.2 volts or inconsistent device operation. Power off the device and open the battery compartment, carefully removing the old battery while noting its orientation. Dispose of the old battery according to local hazardous waste regulations, as Lithium Thionyl Chloride batteries contain hazardous materials. Install a new, tested battery with a voltage of at least 3.6 volts, ensuring correct polarity and secure connection to the terminals or connector. If the device uses multiple batteries, replace all simultaneously to prevent performance issues from mixing old and new cells. Close and seal the compartment, then power on the device to verify functionality, including wireless data transmission. Update the maintenance log with the replacement date and new battery details.
Troubleshooting and Issue Resolution
Address any issues identified during inspections or testing promptly. If the device fails to power on or exhibits intermittent operation, recheck the battery’s voltage and connections, ensuring proper seating and polarity. Clean corroded terminals with a specialized contact cleaner, if necessary but avoid damaging the compartment. If passivation persists after applying a low-current load, replace the battery, as it may be defective. For wireless devices with transmission failures, confirm that the issue stems from the battery rather than network or antenna problems by testing with a known good battery. Consult the device manual or manufacturer for specific troubleshooting steps, and contact technical support if issues persist. Document all troubleshooting actions and outcomes in the maintenance log for future reference.
Safety and Disposal Considerations
Handle batteries with care during maintenance, wearing insulated gloves to prevent short-circuiting, which can cause fire or explosion. Avoid crushing, puncturing, or exposing batteries to temperatures above 100°C. If soldering is required for custom configurations, delegate this to trained professionals to avoid damaging the battery. Store spare batteries in a cool, dry, ventilated area below 30°C to preserve their 10- to 20-year shelf life. Dispose of used or defective batteries through certified hazardous waste facilities, never in regular trash or recycling bins. Ensure compliance with local regulations for transportation and disposal to minimize environmental and safety risks.
Continuous Improvement and Training
Review maintenance logs periodically to identify trends, such as frequent battery replacements or environmental issues, and adjust procedures accordingly. For example, if batteries deplete faster than expected, investigate power consumption or environmental factors. Provide regular training for maintenance personnel on updated safety protocols, battery testing techniques, and device-specific requirements.
Advantages / Disadvantages
Advantages
The high energy density of 3.6V, 19,000mAh Lithium Thionyl Chloride batteries allows them to deliver substantial power in a compact D-size form factor, making them ideal for space-constrained industrial instrumentation like wireless sensors and smart meters. Their exceptional longevity, with operational lifespans ranging from 3 to 20 years depending on usage, reduces the need for frequent replacements, minimizing maintenance costs and downtime in remote or hazardous environments such as oil pipelines or manufacturing plants.
A low self-discharge rate, less than 1% per year at room temperature, ensures these batteries retain charge during long storage periods, supporting a shelf life of 10 to 20 years and making them reliable for backup systems or infrequently used devices. Their ability to operate across a wide temperature range, from -55°C to +85°C, ensures consistent performance in extreme conditions, such as arctic installations or desert facilities, where consumer-grade batteries often fail. The stable 3.6-volt output maintains consistent power delivery throughout the battery’s life, critical for wireless devices like telemetry units that require reliable data transmission.
Robust construction withstands vibration, shock, and humidity, enhancing durability in rugged industrial settings. Compliance with safety standards, including UL recognition and UN transportation tests, ensures safe handling and deployment, reducing risks in critical applications.
Disadvantages
The non-rechargeable nature of these batteries necessitates replacement once depleted, leading to higher long-term costs in applications requiring large quantities or frequent cycling, unlike rechargeable lithium-ion alternatives. Their low discharge rate, typically below 200 milliamps continuously, restricts their use to low-power instrumentation, making them unsuitable for high-drain devices like motors or heavy machinery controllers.
Passivation, a temporary voltage drops after prolonged storage due to a protective layer on the lithium anode, can delay device activation, requiring a brief discharge to restore performance and complicating immediate deployment in time-sensitive applications. The 3.6-volt output exceeds the 1.5 volts of standard alkaline batteries, posing compatibility issues with devices not designed for this voltage, potentially causing damage if mistakenly used in consumer-grade equipment.
Soldering terminals for custom configurations, such as series setups for higher voltages, is challenging and risks damaging the battery, often requiring specialized skills. Quality variability among brands, with some lower-cost options failing prematurely or arriving dead, underscores the need for careful supplier selection to avoid reliability issues.
Safety risks, including fire or explosion if short-circuited, crushed, or exposed to temperatures above 100°C, demand strict handling protocols, particularly in industrial environments with untrained personnel. Disposal of these batteries, containing hazardous materials, requires compliance with stringent regulations, increasing operational complexity compared to less hazardous alternatives.
Q&A
What type of battery is a 3.6V, 19,000mAh battery used in industrial instrumentation?
This is typically a Lithium Thionyl Chloride battery, a non-rechargeable primary cell known for its high energy density and long lifespan. It’s designed for low-power, long-term applications like wireless sensors and smart meters in industrial settings.
Why are these batteries suitable for harsh industrial environments?
They operate reliably across a wide temperature range, from -55°C to +85°C, making them ideal for extreme conditions like arctic pipelines or desert facilities. Their robust construction also withstands vibration, shock, and humidity common in industrial settings.
How long can these batteries last in industrial instrumentation?
Depending on the device’s power consumption, they can last 3 to 20 years. Their low self-discharge rate, less than 1% per year, supports this longevity, reducing maintenance needs in remote or hard-to-access locations.
What are common applications for these batteries in industry?
They power wireless sensors for monitoring temperature, pressure, or flow, smart meters for utilities, remote telemetry units for pipeline integrity, and backup systems for real-time clocks or emergency transmitters in automation and security.
Can these batteries be recharged?
No, they are non-rechargeable. Attempting to recharge them risks fire or explosion, so they must be replaced once depleted, which can increase costs in high-volume applications.
What is passivation, and how does it affect these batteries?
Passivation is a temporary voltage drop caused by a protective layer forming on the lithium anode after long storage. It can delay device activation but is resolved by briefly discharging the battery, such as with a 100mA load for a few minutes.
Are these batteries compatible with all industrial devices?
No, their 3.6-volt output is higher than the 1.5 volts of standard alkaline batteries, so they’re only suitable for devices designed for this voltage. Using them in incompatible devices can cause damage.
What safety precautions should be taken when handling these batteries?
Wear insulated gloves to prevent short-circuiting, avoid crushing or exposing them to temperatures above 100°C, and never attempt to recharge them. Store them in a cool, dry place below 30°C to maintain shelf life.
How should these batteries be disposed of?
They contain hazardous materials and must be disposed of through certified hazardous waste facilities, not regular trash. Compliance with local regulations is essential to ensure safe and environmentally responsible disposal.
What issues might arise during maintenance of these batteries?
Passivation can cause temporary performance issues, and corrosion or loose connections in the battery compartment may disrupt operation. Regular voltage testing and cleaning terminals with a dry cloth can prevent these problems.
Can these batteries support high-power industrial devices?
No, they are limited to low-power applications due to their low discharge rate, typically below 200 milliamps continuously. High-drain devices require alternative power sources like lithium-ion batteries.
How can I ensure I’m using a high-quality battery?
Choose reputable brands like Tadiran, Saft, or PKCELL, and verify certifications like UL recognition or UN transportation compliance. Check user reviews and avoid cheaper options that may fail prematurely.
What should I do if a battery shows low voltage during testing?
If the voltage is below 3.2 volts, try addressing passivation with a brief low-current load. If it doesn’t recover, replace the battery, as it may be nearing the end of its life or defective.
How often should I inspect devices using these batteries?
Inspect every six months or per the device manual. Check for physical damage, test voltage with a multimeter, and ensure the compartment is sealed to protect against environmental factors.
What happens if I mix old and new batteries in a device?
Mixing old and new batteries can reduce overall performance and lifespan, as the older cells may deplete faster, causing inconsistent power delivery. Always replace all batteries simultaneously.
Applications
These batteries are ideal for wireless industrial instrumentation, where reliable, long-term power is critical for devices operating in remote or challenging environments. Common applications include:
Wireless Sensors and Transmitters
Power wireless sensors for temperature, pressure, flow, or vibration monitoring in industrial settings like oil and gas, manufacturing, or utilities.
Support low-power, periodic data transmission over wireless protocols (e.g., LoRa, Zigbee, or proprietary systems).
Remote Monitoring Systems
Used in remote telemetry units for environmental monitoring, pipeline integrity, or infrastructure health.
Long lifespan reduces maintenance costs in hard-to-access locations.
Power water, gas, or electricity meters that transmit usage data wirelessly.
High capacity ensures years of operation without battery replacement.
Support wireless devices in automated systems, such as door opening detectors, alarm systems, or asset tracking equipment.
Provide memory backup for CMOS memory, real-time clocks (RTC), or emergency locator transmitters (ELTs) in industrial equipment.
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