valve regulated lead-acid battery gts- series gts manual.pdf · gts-300 0.363 5588 gts-400 0.297...

GasTon®

VALVE REGULATED LEAD-ACID BATTERY

GTS- SERIES

OPERATION MANUAL

GASTON BATTERY INDUSTRIAL LTD.

1999.7

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! We really appreciate your wise choice of GTS series Valve-Regulated

Lead-Acid battery. This manual will give you instructions on how to

install, operate and maintain GTS battery, so that the battery can give

a best performance.

! Please carefully read all instructions in this manual before you

proceed with installation. And please keep the manual for reference

during operation.

! It is forbidden to overcharge battery shortly and short circuit shall be

avoided. Please do not attempt to dismantle the battery if some

abnormal phenomena happen. You should contact us immediately and

our technicians will handle the problems or replace the battery in

time.

The manufacturer reserves the right to make alterations without

prior notice concerning the operation manual.

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Contents

ⅠⅠⅠⅠ. Brief Introduction--------------------------------------------------1 1. Features -------------------------------------------------------------------1 2. Indication of Type -------------------------------------------------------2 3. Types and Dimensions --------------------------------------------------2 II. Technical Characteristics ----------------------------------------3 1. Capacity and Influence Factor -----------------------------------------3 2. Temperature and Floating Voltage ------------------------------------5 3. Internal resistance and short circuit current--------------------------6 4. Type Selection -----------------------------------------------------------6 III. Installation -----------------------------------------------------------8 1. Installation Mode and Occupied Area of Battery Group ---------- 8 2. Installation Precautions -------------------------------------------------9 3. Installation Procedure ---------------------------------------------------10 ⅣⅣⅣⅣ. Operation --------------------------------------------------------------22 1. Condition ----------------------------------------------------------------- 22 2. Floating Operation -------------------------------------------------------22 3. Equalized Charge --------------------------------------------------------22 4. Charge ---------------------------------------------------------------------22 5. Storage --------------------------------------------------------------------24 ⅤⅤⅤⅤ. Maintenance ---------------------------------------------------------25 1. Monthly Maintenance ---------------------------------------------------25 2. Quarter Maintenance ----------------------------------------------------25 3. Yearly Maintenance -----------------------------------------------------25 4. Three-years Maintenance ---------------------------------------------25 5. Operation and Maintenance Precautions -----------------------------25

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I. Brief Introduction

1. Features 1.1 Basic Characteristics 1) Adopts the design of barren-electrolyte and utilizes AGM (microporous glass fiber) separator.

Thus there is a path existing between the positive and the negative. Also non-Sb alloy grid is chosen to increase vent hydrogen over-potential on the negative plate, which prevent generation of Hydrogen, finally reaches the goal of no water losing. So during the operation life, theres no need to add acid and water, neither to adjust the gravity of the solution.

2) Reliable seal performance, not emission of acid mist, not erosion to equipment. 3) Long life and low self-discharge. 4) Compact structure, shock-proof and high energy density design. 1.2 Reliable Seal Technology 1) Container and lid made of reinforcing ABS plastic. Adopt heat seal technology of ABS

container and lid. The technology conquers epoxys weaknesses of aging and brickle. And the amalgamation of the same ABS material ensures no leakage of solution.

2) Explosive proof valve with an acid filtering structure. If the pressure inside the battery exceeds a certain value, the safety valve will automatically open to decrease the pressure. And it will close till the pressure is normal. The acid filtering structure in the safety valve prevents emission of acid mist when the safety valve opens.

3) Excellent resist characteristics of mechanical impact and heat impact, prolong the corruption distance of sulfuric acid.

1.3 Excellent high rate discharge performance 1) Unique multiple-segment radial grid 2) Copper insert pillar, the copper inserts diameter is as long as 20mm, suitable for high rate

discharge 3) Silver-coated flexible connector, good electric performance and low voltage-decrease. 1.4 Extremely equalized float charge voltage A unique homogeneous working procedure ensures homogeneous float charge voltage of GTS batteries.

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Fig. 1-1 Cell Construction

2. Indication of Type G T S × × × × 10Hr CAPACITY RATE STATIONARY

GASTON BATTERY

3. Types and Dimensions

Rated Capacity (Ah) Dimensions(mm) Cell Type

Rated Voltage

(V) C10 C3 C1 Length Width Height Overall Height

Weight (Kg)

GTS-200 2 200 150 110 120 200 366 385 16 GTS-300 2 300 225 165 161 200 366 385 23 GTS-400 2 400 300 220 201 200 366 385 30 GTS-500 2 500 375 275 242 200 366 385 38 GTS-600 2 600 450 330 283 200 366 385 45 GTS-800 2 800 600 440 183 244 604 624 62 GTS-1000 2 1000 750 550 218 244 604 624 76 GTS-1500 2 1500 1125 825 305 244 604 624 111

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II. Technical Characteristics

1. Capacity and Influence Factor 1.1 Capacity of Battery The capacity of battery is the capacity that battery can be discharged on the established conditions, expressed as signal C. The usual unit of capacity is ampere hour, shortened as AH. The capacity can be expressed in Rated Capacity or Actual Capacity. The Rated Capacity of GASTON GTS I battery please see Table 1-1. The Actual Capacity is the product of the discharge current and the discharge time, the unit is AH. 1.2 The Influence Factor of the Actual Capacity The actual capacity is mainly related with the positive and negative active materials and their utilization rate. The utilization rate of the materials is mainly influenced with the DOD, the structure of the battery and manufacture technology. In using process the factors that influence the actual capacity are discharge rate, discharge modality, end voltage and temperature. 1.2.1 Discharge Rate The discharge rate is often described as hour-rate and multiple rates. Figure 2-2 is the discharge characteristics curves at different discharge rates. From the figure we can see that when we adopt same type battery to discharge, if the discharge rate is higher and the discharge current is larger, then the discharge time is shorter, and the capacity which can be discharged is less.

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Fig. 2-1 Discharge Performance Curves at Different Discharge Rates (25)

1.2.2 Temperature Temperature affects capacity of the battery. Fig. 2-2 is the available capacity curve vs. ambient temperature. If the ambient temperature is not 25 , its necessary to change the measured capacity to actual capacity Ce at 25according to following formula:

Ce = CT /(1 + K (T-25)) T the ambient temperature K temperature modulus, 10hr rate capacity test K=0.006/ 3hr rate capacity test K=0.008/ 1hr rate capacity test K=0.01/

Fig. 2-2 Available Capacity VS. Ambient Temperature

Discharge Time(h)

Voltage/Cell (V)

0.01

1.7

1.6

1.9

1.8

2.1

2.0

105210.50.20.10.02 5020

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1.2.3 End voltage The end voltage is the lowest working voltage below which the battery cant be discharged any more. Usually the 10hr rate end voltage of lead-acid battery is 1.80V, and the 3hr rate and 1hr rate end voltage are 1.75V.

2. Temperature and Floating Voltage 2.1 Ambient Temperature The best ambient temperature of using GASTON GTS battery is 25. At 25, GASTON battery can be discharged 100% of its capacity. If the ambient temperature is different, it can be improved with methods as follows:

Change the environment, such as adopting cooling system, changing the position of the batteries, and improve ventilation.

Adopt temperature revising method, if the ambient temperature is higher, decrease the floating charge voltage; if lower, increase the floating charge voltage.

2.2 Floating Voltage The purpose of choosing certain floating voltage is to reach the designed life and rated capacity of

-20 -10 0 10 20 30 40 5050

60

70

80

90

100

110Capacity (%)

Ambient Temperature（）

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the battery. If the floating voltage is higher, then the floating current is also higher, it will accelerate the corruption the grid and shorten the life of the battery. If the floating voltage is lower, the battery cant be kept in full charged state, this will crystallize PbSO4, decrease the capacity, and also shorten the life of the battery. At 25, if the floating voltage is 2.23±0.02V/cell, the designed use life of GASTON GTS battery is 15 years. In other degree, please adjust according to Table 4-2.

3. Internal resistance and short circuit current The internal resistance of the battery is a dynamic nonlinear parameter that is continuously changed along with the temperature and discharge state. The internal resistance is the lowest when battery is full charged. The table 2-1 shows the internal resistance and short circuit current of GASTON battery in fully charged state according to the DL/T 637-1997 standard of Chinese Electric Power Department. Table 2-1. Internal resistance and short circuit current (25)

Battery Type Internal resistance (mΩ) Short circuit current (A) GTS-200 0.514 3940 GTS-300 0.363 5588 GTS-400 0.297 6816 GTS-500 0.218 9361 GTS-600 0.175 11576 GTS-800 0.223 9153 GTS-1000 0.189 10804 GTS-1500 0.152 13237

Note: Short circuit current will decrease the voltage of the battery to 0V, and damage the internal components of the battery.

4. Type Selection Please select batteries capacity according to Fig. 2-3 Selection Curve of Cell Type. 1) First confirm the discharge current and end voltage. E.g., required constant current output is 125A and the end voltage is1.80V. 2) Confirm the continual working time and ambient temperature. E.g., the continual working time is 3 hours, and the ambient temperature is 25. 3) Select right battery type according to Fig. 2-3 when the discharge current is 125A and the

discharge time is 3 hours: the minimum capacity is 500Ah. Fig. 2-3 Selection Curve of Cell Type

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35

10152030

50

100150200300

500

1000150020003000

单体电池 (终止电压 1.80V/单体 ) T=25

小时分

5min 15min10min 30min40min 60min 2h 3h 5h 10h

200

300400500600800100015002000

3000

3000

20001500

8001000

500400

600

300

200Ah(10HR)

放

电

电

流

(A)

放电时间

MONO CELL BATTERY(end discharge voltage 1.8v/cell) T=25

Discharge time

Discharge current(A

)

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III. Installation

1. Installation Mode and Occupied Area of Battery Group Table 3-1 Installation Mode and Occupied Area of GTS-200 --- GTS-600 Series Battery Group

Installation Mode Installation Mode Horizontal Mode Vertical Mode

Battery Type

Floor(s) Voltage (V)

Total Weight (Kg)

Occupation Area L x W x H (mm)

Floor(s) Voltage(V)

Total Weight (Kg)

Occupation Area L x W x H

(mm) 2 24 253 930x344x573 1 24 253 1478x336x596 2 48 491 1820x344x573 2 24 245 739x336x1120 3 24 245 600x344x833 2 48 491 1478x336x1120 3 48 491 1210x344x833 3 48 461 952x336x1650 4 24 253 460x344x1093 4 48 506 930x344x1093

GTS-200

6 48 491 600x344x1613 2 24 344 1176x344x573 1 24 424 1478x498x596 2 48 673 2312x344x573 2 24 615 739x498x1120 3 24 336 764x344x833 2 48 829 1478x498x1120 3 48 673 1538x344x833 3 48 796 952x498x1650 4 24 344 583x344x1093 4 48 689 1176x344x1093

GTS-300


GTS-400


GTS-500


GTS-600

6 48 1229 1252x344x1613 * Total weight and occupation area for reference only.

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Table 3-2 Installation Mode and Occupied Area of GTS-800 --- GTS-1500 Series Battery Group

Installation Mode Horizontal Mode

Battery Type

Floor(s) Voltage (V)

Total Weight (Kg)

Occupation Area L x W x H (mm)

2 24 827 1308 x 579 x 661 2 48 1650 2576 x 579 x 661 3 24 827 852 x 579 x 965 3 48 1650 1714 x 579 x 965 4 24 827 694 x 579 x 1269 4 48 1650 1308 x 579 x 1269

GTS-800

6 48 1650 852 x 579 x 1877 2 24 1018 1518 x 579 x 661 2 48 2036 2996 x 579 x 661 3 24 1018 992 x 579 x 965 3 48 2036 1994 x 579 x 965 4 24 1018 754 x 579 x 1269 4 48 2036 1518 x 579 x 1269

GTS-1000

6 48 2036 992 x 579 x 1877 2 24 1420 2040 x 579 x 661 2 48 2840 4040 x 579 x 661 3 24 1420 1340 x 579 x 965 3 48 2840 2690 x 579 x 965 4 24 1420 1015 x 579 x 1269

GTS-1500

4 48 2840 2040 x 579 x 1269 * Total weight and occupation area for reference only.

2. Installation Precautions ! The customer can adopt flexible installation methods according to the condition of

installation area. However detailed requirements about installation shall be submitted when placing the order so that best connection scheme can be determined and installation drawings can be provided.

! GTS-200 --- GTS-600 series batteries can be installed in vertical or horizontal mode, GTS-800 --- GTS-1500 series batteries must be in installed in horizontal mode.

! Please strictly refer to installation drawings when make serial and connection. ! Batteries of different capacity and performance can not be connected together. ! Batteries must be strictly series-wound or shunt-wound connected according to installation

drawing. ! Use insulating instruments during installation. ! It is forbidden to place the vertical batteries horizontally without putting foamed plastics

under it. ! Do not use large torque to connect batteries. ! Installation of abnormal batteries is prohibited. ! Batteries are of sealed structure, in normal condition, theres no danger of cauterization of

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sulphuric acid. But if batteries are broken in transportation or unloading, wash cauterized skin and/or eyes with plenty of water immediately, and the person should be sent to hospital as quickly as possible.

! The batteries system should be installed nearer to the load as possible as it can, in orders to avoid voltage drop of the wire.

! After installation, check again the system voltage, the polarity of positive and negative post to ensure the correct installation.

3. Installation Procedure 3.1 Check battery to assure no damage after unpacking, check accessory against packing list to

assure completeness. 3.2 Installation of battery frame 3.2.1 Installation of vertical battery frame For example, install (48V) system. a) As per Fig. 3-1, fix foot-board, two side-boards and one shelf-board with M8 bolts. Finish

installation of first-floor battery frame.

b) According to Fig. 3-2, fix two side-boards, one shelf-board, first floor side frame, finish

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installation of second-floor battery frame. Use the same method to fix third floor battery frame.

c) According to Fig. 3-3, fix one insulating board, two electric conductive boards with M8 bolts

to form connector of batteries and terminal board of accordant junction.

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d) According to Fig. 3-4, fix upper-frame and third floor side-board. Note: Holes should be made previously by the customers if the derivative wires are set upwards.

e) According to Fig. 3-5, insert baffle-board (it should be done after batteries are already put on

the battery frame). Finish the installation of three layers battery frame.

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Note: 1) In order to ensure steadiness of the whole battery frame, do not screw bolts tightly during the process in order to make adjustment, finally screw tightly after adjustment. 2) The customers, who want to install chassis bolts, should first fix the chassis bolts on the ground, then fix the battery frame with the bolts.

3.2.2 Installation of Horizontal Battery Frame For example, install (48V) system. a) According to Fig. 3-6, fix two foot slats and iron box with M8 bolts, finish the first floor battery box.

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b) According to Fig. 3-7, fix the second iron box with same method, finish installation the second floor iron box. Use same method to fix up the third, fourth, fifth and sixth iron boxes.

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c) According to Fig. 3-8, fix connector of batteries and terminal board of accordant junction with M8 bolts.

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Fig. 3-8 d) According to Fig. 3-9, put cover-board on the finished battery frame, then finish installation. Note: (1) In order to ensure steadiness of the whole battery frame, do not screw bolts tightly during installation in order to make adjustment, finally screw tightly after adjustment. 2) The customers, who want to install chassis bolts, should first fix the chassis bolts on the ground, then fix the battery frame with the bolts.

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3.3 Installation of Batteries (1) Emplace batteries floor by floor or line by line, see Fig. 3-10 or Fig. 3-11. Note to check the

polarity of positive and negative post. (2) According Fig. 3-10, Fig. 3-11 to connect the line of batteries. The connect mode of connector

see Fig. 3-12, use torque wrench to screw tightly, the torque is 15Nm.

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IV Operation

1. Condition The GTS battery can be used in -15---+45 of the ambient environment. The best ambient temperature is 25.

2. Floating Operation GASTON GTS battery can be either floating used or cycle used. Floating using is the best operation condition of the battery. The battery is all the while

fully charged in operation, in this condition battery can be used for longest life. During floating operation, please adjust the charge voltage according to environmental temperature, see Table 4-1:

Table 4-1 Floating Voltage VS. Ambient Temperature

Environmental Temperature () Floating Voltage ( V±0.02V/Cell) 010 2.29 1115 2.26 1625 2.23 2630 2.21 3135 2.20 3640 2.19

3. Equalized Charge GASTON GTS battery need to be equalized charge on conditions as follows:

After installation of the battery system, the batteries need to be supplemental charged. Floating operation over three months, and the voltage of at least two batteries are lower

than 2.18V. Storage over three months. Floating operation for three months. The method of equalized charge is suggested as follows: Charge with 2.35V2.40V/Cell for 24 hours. Note: Above-mentioned charge time is on condition that temperature changes from 20to

30.If the ambient temperature decreases, its better to increase the charge time; otherwise, decrease the charge time.

4. Charge

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After discharge, the batteries should be charged in time. The method is recommended as follows: The batteries first should be charged on the constant current of 0.1C10A till the average

voltage of the batteries increases to 2.352.40V, then the batteries should be charged with constant voltage of 2.352.40V/Cell, till the charge is finished.

Whether the batteries are fully charged can be decided according to any one of two standards as follows:

The charge time is 1824 hours (the charge time can be shortened when the batteries werent deep discharged, e.g. , the charge time of 20% DOD batteries can be shortened to 10hours.)

On condition of constant voltage, the value of charge current hasnt varied for continuous three hours.

On special condition, the batteries need to be fully charged as soon as possible, then fast charge should be adopted: the value of limit current should not be longer than 0.25C10A, and the charge voltage should be 2.352.40V per cell. Fig. 4-1 shows recharge characteristics curve of 100% DOD GTS-500 batteries with 0.1C10A current and limit voltage 2.35V/Cell (25). It can be found the fully discharged batteries can be charged 100% capacity in 15 hours. Fig. 4-2 shows recharge characteristics curve of 100% DOD GTS-500 batteries with 0.1C10A current and limit voltage 2.23V/Cell (25). It can be found the fully discharged batteries can be charged 100% capacity in 24 hours. Fig. 4-1 Recharge Characteristics Curve of 100% DOD GTS-500 Batteries with 0.1C10A Current and Limit Voltage 2.35V/Cell (25))))

0 5 10 15 20 25 301.9

2.0

2.1

2.2

2.3

2.4Charging Voltage Per Cell

Capacity Charged

Charging Current

Per CellCharging Voltage

(V)

Charging Time (h)

0

10

20

30

40

50

60

70

ChargingCurrent (A)

0

20

40

60

80

100

120

140

CapacityCharged (%)

24

Fig. 4-2 Recharge Characteristics Curve of 100% DOD GTS-500 Batteries with 0.1C10A Current and Limit Voltage 2.23V/Cell (25))))

5. Storage All lead acid batteries self-discharge in open circuit. The result is that the voltage of open circuit is decreased, and the capacity also decreased. During storage please note:

The self-discharge rate is related with ambient temperature. The self-discharge degree is smaller when the ambient temperature is lower, otherwise is larger. The requirement temperature of GASTON GTS batteries storage environment is from 0 to 35. The storage place must be clean, ventilated and dry.

An important parameter in storage is open circuit voltage, which is related with density of the electrolyte. In order to avoid perpetual damage to the plate caused by self-discharge, the batteries should be supplemental charged if they have been stored for

0 5 10 15 20 25 30 1.9

2.0

2.1

2.2

2.3

Charging Per Cell (V)

Charging （ h ）

0

20

40

60

80

100

120

140

Charging Voltage Per

Charging

Capacity

Charged (%)

0

10

20

30

40

50

60

70

Charging Capacity Current (A)

25

three months. The equalized charge method should be adopted. During storage, if the open circuit voltage is lower than 2.10V/Cell, the batteries should

be supplemental charged before use. The equalized charge method should be adopted. All batteries, which are ready to store, should be fully charged before storage. Its

suggested record the storage time in the periodic maintenance record and record the time when another necessary supplemental charge should be made.

The quality certificates of GTS batteries record the latest charge time of the batteries, the next charge time can be calculated according to this charge time.

V Maintenance In order to assure life, the batteries should be correctly inspected and maintained. The maintenance methods of GTS batteries is recommended as follows:

1. Monthly Maintenance Implement the under-mentioned inspection every month:

Keep the battery-room clean. Measure and record the ambient temperature of the battery-room. Check each batterys cleanness, check damage and calorific trace of the terminal,

container and lid. Measure and record the total voltage and floating current of the battery system.

2. Quarter Maintenance Repeat monthly inspection. Measure and record floating voltage of every on-line battery. If more than two cells

voltage is less than 2.18V after temperature adjustment, the batteries need to be equalized charged. If the problem is still existed after adopting such measures, the batteries need to yearly maintenance or even three years maintenance. should be processed If all methods are ineffective, please contact us.

3. Yearly Maintenance Repeat quarter maintenance and inspection. Check whether connectors are loose or not every year. Make a discharge test to check with exact load every year, discharging 30-40% of rated

capacity.

4. Three-years’ Maintenance Make a capacity test once every three years and once every year after six years operation.

If the capacity of the battery decreases to lower than 80% of rated capacity, the battery should be replaced.

5. Operation and Maintenance Precautions Use insulating instruments in operating and maintaining batteries. Do not lay metal

instruments on batteries. Do not use any organic cleanser to clean batteries.

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Do not dismantle the safety valves of batteries and add anything into batteries. Do not smoke or use fire near batteries. Do not use abnormal batteries. (E.g., fast inflation, serious transmogrification and vent

valve detonation.) All maintenance works should be done by professionals.

valve regulated lead-acid battery gts- series gts manual.pdf · gts-300 0.363 5588 gts-400 0.297...

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