Green Rhino CRYSTAL 6-GREV-180 User manual

USER MANUAL - SAFETY, STORAGE, OPERATIONS AND MAINTENANCE
WWW.GREENRHINO-ENERGY.COM [email protected]

|
2CRYSTAL® BATTERY USER MANUAL
GREEN RHINO USER MANUAL
This manual provides full instructions regarding safety, storage, operation, and maintenance for Crystal®
batteries, as well as certain installation considerations. Failure to observe the precautions as presented
may result in damage to equipment, injury, or loss of life.
© 2020 BY GREEN RHINO. ALL RIGHTS RESERVED.
This document is proprietary to and copyright of Green Rhino. This document cannot be copied or reproduced in
whole or in part without the express written permission of Green Rhino.
Green Rhino reserves the right to make updates and changes to any and all product-related documentation with
or without informing distributors, resellers, and users. Please check our website (www.greenrhino-energy.com)
regularly for literature updates, document changes, and prole updates.

|3
CRYSTAL® BATTERY USER MANUAL
SYMBOLS FOR BATTERY USE AND
OPERATION
Please read chapter 5 for further details on safety
guidelines.
SAFETY WARNING
ELECTRICAL HAZARD
EYE PROTECTION
SHORT CIRCUIT PREVENTION
ADULT SUPERVISION REQUIRED
READ THE MANUAL
NO OPEN FLAMES OR SPARKS
RECYCLE
DO NOT DISPOSE OF BATTERIES INTO THE
TRASH
THIS PRODUCT HAS PASSED UL
SAFETY CERTIFICATION
THIS PRODUCT HAS PASSED CE
CERTIFICATION
THIS PRODUCT HAS PASSED IEC/EN
60896-21/22
SHOCK HAZARD
RISK OF EXPLOSION
SAVE THESE INSTRUCTIONS
Important! Please read this manual as it
contains important instructions that should be
followed during storage, installation, operation, and
maintenance of Crystal® batteries. Following the
manual will help achieve the highest performance
of your equipment and extend the lifetime of your
product.
1. Battery handling and servicing should be per-
formed or supervised by personnel who have
professional knowledge about batteries and
precautionary measures. Battery replacement
by unauthorized personnel is prohibited. When
replacing batteries, please use Crystal® batteries
of the same capacity and size as originals used in
equipment.
2. Do not misuse or disassemble / deconstruct
Crystal® batteries, this could result in human
injury or cause damage to the batteries. In no
event will Green Rhino be responsible or liable
for either indirect or consequential damage or
injury that may result from misuse, abuse, or
disassembly / deconstruction of batteries.
3. Crystal® batteries contain a small amount of
sulphuric acid (< 3%). Sulphuric acid can be
harmful to the skin and eyes if not handled
with care. Take precautionary measures as
described in this manual.
4. It is important to handle batteries correctly when
returning batteries. As the batteries contain lead,
any inappropriate handling of the batteries will
have adverse effects on the environment and on
persons. Please check local legislation to obtain
approved handling procedures or return batteries
to authorized service centers of the manufacturer
for replacements and discarding.
5. Do not place batteries in or near a direct re,
open ame, or any source of heat.
6. Do not use an organic solvent to clean batteries.
7. Batteries may cause electric shock and burns
when short-circuited. Always use tools with
insulated handles when installing, changing, or
maintaining Crystal® batteries.
GENERAL SAFETY INSTRUCTIONS

|
4CRYSTAL® BATTERY USER MANUAL
TABLE OF CONTENTS
1. GENERAL INFORMATION.......................................................................................................................................6
1.1 Introduction.......................................................................................................................................6
1.2AdvantagesSummarized....................................................................................................................6
1.3 Applications......................................................................................................................................7
14. Product Specication and Model Identication...................................................................................7
1.5 Battery families.................................................................................................................................7
1.6 Product Standards.............................................................................................................................8
1.7Productrange....................................................................................................................................8
2.TECHNICALSPECIFICATIONS................................................................................................................................12
2.1StructureCharacteristics..................................................................................................................12
2.1.1 Special Electrolyte Composition.......................................................................................12
2.1.2 Battery enclosure............................................................................................................12
2.1.3.Grid and Plates ..............................................................................................................12
2.1.4 Seperator- Super Absorbent Matt (SAM)..........................................................................12
2.1.5 Safety Valve....................................................................................................................12
2.1.6 Sealing Performance.......................................................................................................12
2.1.7 Plate Performance...........................................................................................................12
2.1.8 Special Manufacturing Process........................................................................................13
2.2 Generic Working Principle................................................................................................................13
3. CHARGE AND DISCHARGE SPECIFICATIONS.....................................................................................................14
3.1 Charge Characteristics GRGS, HGRGS, GRFT,GRLS............................................................................15
3.1.1 GRGS, HGRGS, GRFT 12-Volt Cyclic Charge Specications..................................................16
3.1.2 GRGS, HGRGS, GRFT 12-Volt Float Charge Specications...................................................17
3.1.3 GRGS 6-Volt Cyclic Charge Specications.........................................................................18
3.1.4 GRGS 6-Volt Float Charge Specications..........................................................................19
3.1.5 GRLS 2-Volt Cyclic Charge Specications..........................................................................20
3.1.6 GRLS 2-Volt Float Charge Specications..........................................................................21
3.2 Charge Characteristics GREV...........................................................................................................22
3.2.1 GREV 12-Volt Cyclic Charge Specications........................................................................23
3.2.2 GREV 8-Volt Cyclic Charge Specications..........................................................................24
3.2.3 GREV 6-Volt Cyclic Charge Specications..........................................................................25
3.3 Purication Charging.......................................................................................................................26
3.4 Battery Life andTemperature...........................................................................................................26
3.4.1 Minimum and Maximum Temperatures............................................................................26
3.4.2 Temperature Compensations when Charging....................................................................27
3.5DischargeCharacteristics.................................................................................................................27
3.5.1 Battery Capacity...............................................................................................................27
3.5.2 Battery Discharge Rate....................................................................................................27
3.5.3 Inuence of Tempeature on Capacity...............................................................................28
3.5.4 Discharge Voltage...........................................................................................................28

|5
CRYSTAL® BATTERY USER MANUAL
TABLE OF CONTENTS
4. TRANSPORT, STORAGE AND INSTALLATION...................................................................................................29
4.1BatteryTransport.............................................................................................................................29
4.2 BatteryStorage...............................................................................................................................29
4.3 Battery Installation.........................................................................................................................30
5. OPERATIONS AND MAINTENANCE.....................................................................................................................31
5.1BatteryMaintenance........................................................................................................................31
5.1.1 Quarterly Maintenance....................................................................................................31
5.1.2AnnualMaintenance........................................................................................................31
6. SAFETY GUIDE........................................................................................................................................................32
6.1GeneralSafety.................................................................................................................................32
6.2 Safety Equipment and Clothing.......................................................................................................32
6.3SafetyPrecautions...........................................................................................................................32
6.3.1SulphuricAcidBurns........................................................................................................32
6.3.2 Explosive Gasses.............................................................................................................32
6.3.3 Electrical Shocks and Burns.............................................................................................33
7. TROUBLESHOOTING.............................................................................................................................................34
8. CUSTOMER SERVICE.............................................................................................................................................37
8.1 Crystal® batteries authorized distributors and dealers.....................................................................37

|
6CRYSTAL® BATTERY USER MANUAL
process, crystalline inorganic salts are formed, and
the liquid electrolyte is converted into crystallized
salt. The electrolyte is distributed evenly throughout
the cell in a non-hierarchical manner, and there is
no gradient concentration in the upper and/or lower
electrode. This improvement gives complete cell
saturation and assists Crystal® batteries in
achieving an even charge distribution over the
entire plate, improving the electrical properties of the
battery and providing consistent and reliable
performance. It effectively overcomes the
disadvantages of plate sulphation, prevents active
material loss, reduces water loss, has good
temperature range resilience, overcharge/discharge
performance, in addition to greatly improved
battery life.
1.2 ADVANTAGES SUMMARIZED
Compared to mainstream rechargeable industrial
batteries like Lead Acid, Lead Gel, and AGM batteries,
Crystal® batteries have signicant improvements:
• Crystal® batteries can charge faster
• Crystal® batteries can be discharged deeper
(even to 0 Volts!)
• Crystal® batteries do not suffer thermal runaway.
• Crystal® batteries have an operating
temperature range from -40˚C (-40˚F) to
65˚C (149˚F)
• Crystal® batteries can be charged in subzero
conditions.
• Crystal® batteries can be cycled more often, even
@ 80% DOD)
• Crystal® batteries have very low gassing
(IEC 60896-21/22)
• Crystal® batteries can be used in a partial state
of charge.
• Crystal® batteries can be stored for 2 years at
25˚C (77˚F)
• Crystal® batteries hold no cadmium, no
antimony, and <3% sulphuric acid
• Crystal® batteries operate at higher
temperatures with lower cycle loss
NOTE: Deep discharging, operating in a partial state
of charge and operating above 25˚C (77˚F) will impact
the number of battery cycles. Please refer to the
product datasheets for more detailed information.
1.1 INTRODUCTION
By its unique technology Crystal® batteries have a
higher performance. To overcome the fundamental
limitations of the lead-acid and gel batteries, Green
Rhino has successfully developed technological inno-
vations that make Crystal® batteries ideal
products to replace Lead Acid and Lead Gel batteries.
The safety properties of Crystal® batteries and the
positive test results and case studies from
multinational corporate clients have helped the
Green Rhino Crystal® batteries brand to successfully
enter various global markets.
Crystal® batteries are widely used across a variety
of dynamic applications. Our new type of environ-
mentally friendly battery product is rapidly blending
into the consumer lifestyles of many industries and is
widely accepted by institutions and individuals.
The patented technology found in Crystal® batteries
is a unique and advanced formula - a new type of
composite SiO2 electrolyte developed to completely
replace traditional sulphuric acid solutions. This
secret recipe improves the product’s application
range and safety performance. When the composite
electrolyte reacts with the plates during the charging
1. GENERAL INFORMATION

|7
CRYSTAL® BATTERY USER MANUAL
1.4 PRODUCT SPECIFICATION AND MODEL
IDENTIFICATION
Model identication
12 - GR - GS - 100
Model identication
Battery Congurations
Our battery range consists of 2-volt cells, 6-volt
blocks, 8-volt blocks, and 12-volt blocks. Blocks refer
to a number of 2-volt cells in an enclosed case to
complete a battery.
1 x 2V = 2 Volt Battery
3 x 2V = 6 Volt Battery
4 x 2V = 8 Volt Battery
6 x 2V = 12 Volt Battery
1.5 BATTERY FAMILIES
Crystal® batteries are grouped into 4 families, where
each family addresses a different market and
applications.
1.3 APPLICATIONS
Crystal® batteries can be used in a wide range of
applications where Lead Acid, Lead Gel, AGM or
Lithium batteries are used today, including, but not
limited to:
• Telecommunications, Communications Exchanges
and Transmission Tower Systems;
• UPS (Uninterruptible Power Supply), PABX,
Microwave Relay Stations and Data Centers;
• Radio and Broadcasting Stations;
• Hybrid systems, Power Plants, Substations and
Transmission Systems;
• Emergency Lighting Systems;
• Railway Signal and Beacon Signaling System;
• Solar Energy and Wind Energy Storage Systems;
• Hotels, Auditoriums, Building Automation, and
other Applications;
• Recreational and Off-Road Vehicle Applications;
• Motive and Electrical Vehicles;
• Marine (powered, sail and shipping);
• Security, Surveillance, Remote Monitoring, and
Fire systems;
• Residential and commercial energy storage
power systems.
• Military.
6V, 8V or 12V, rated at 3h discharge
From medium to high capacity
(27Ah to 265Ah)
6V or 12V, rated at 10h discharge
From small to high capacity
(7Ah to 200Ah)
12V, rated at 10h discharge
Front terminal only
(55Ah to 180Ah)
2V, rated at 10h discharge
For high capacity banks
(100Ah to 3000Ah)
ELECTRIC VEHICLE RANGE
GENERAL STORAGE RANGE
FRONT TERMINAL RANGE
LARGE STORAGE RANGE
1
2
3
4

|
8CRYSTAL® BATTERY USER MANUAL
2.
3.
6-GREV-210
6-GREV-265
6-GREV-1801.
6 VOLT
265
6 V
6 V
6 V
180
210
RATED
VOLTAGE
BATTERY NAME RATED AH
3 HR RATE
330
248
280
RATED AH
20 HR RATE
46.5 kg / 102.5 lbs
33 kg / 72.8 lbs
36 kg / 79.4 lbs
WEIGHT
L260 mm (10.2”) W180 mm (7.1”)
H275 mm (10.8”)
L260 mm (10.2”) W180 mm (7.1”)
H275 mm (10.8”)
L295 mm (11.6”) W175 mm (6.9”)
H350 mm (13.8”)
DIMENSIONS
8-GREV-1351.
8 VOLT
8 V 135
RATED
VOLTAGE
BATTERY NAME RATED AH
3 HR RATE
178
RATED AH
20 HR RATE
34 kg / 75 lbs
WEIGHT
L261 mm (10.3”) W182 mm (7.2”)
H285 mm (11.2”)
DIMENSIONS
2. 12-GREV-40
12-GREV-271.
12 VOLT
12 V
12 V
27
40
RATED
VOLTAGE
BATTERY NAME RATED AH
3 HR RATE
34
49
RATED AH
20 HR RATE
9.5 kg / 20.9 lbs
12.5 kg / 27.6 lbs
WEIGHT
L175 mm (6.9”) W166 mm (6.5”)
H125 mm (4.9”)
L222 mm (8.7”) W120 mm (4.7”)
H175 mm (6.9”)
L260 mm (10.2”) W169 mm (6.7”)
H215 mm (8.5”)
L260 mm (10.2”) W169 mm (6.7”)
H215 mm (8.5”)
L331 mm (13”) W176 mm (6.9”)
H219 mm (8.6”)
L330 mm (13”) W172 mm (6.8”)
H255 mm (10”)
L484 mm (19.1”) W170 mm (6.7”)
H241 mm (9.5”)
4. 12-GREV-70
12-GREV-603. 12 V
12 V
60
70
77
86
22.3 kg / 49.2 lbs
25.5 kg / 56.2 lbs
6. 12-GREV-120
12-GREV-1005. 12 V
12 V
100
120
124
151
34 kg / 75 lbs
40 kg / 88.2 lbs
12-GREV-1507. 12 V 150 183 49 kg / 108 lbs
DIMENSIONS
1.7 PRODUCT RANGE
ELECTRIC VEHICLE RANGE - GREV
1.6 PRODUCT STANDARDS
Crystal® batteries are manufactured to meet the following national and international standards and are
manufactured under the ISO 9001, ISO 14001, and ISO45001 (OHS) system.
• IEC/EN 60896 -21/22 Battery Standards
• UL 1989 Standard for Battery Safety
• BS 6290-4 Lead Acid Stationary Cells and Batteries
• SR 4228 Battery String Safety and Performance
• GB/T22473-2008 lead-acid energy storage battery
• GB/T19638.2-2005 xed type valve-controlled sealed battery
• Q/TDZG05-2010 xed type valve control sealed Crystal® battery

|9
CRYSTAL® BATTERY USER MANUAL
2.
3.
4.
6-GRGS-7.2
6-GRGS-10
6-GRGS-12
6-GRGS-41.
6 VOLT
10
12
6 V
6 V
6 V
6 V
6 V
4
7,2
6-GRGS-1605. 160
RATED
VOLTAGE
BATTERY NAME RATED AH
10 HR RATE
12
13,2
4,5
7,8
175
RATED AH
20 HR RATE
1.75 kg / 3.9 lbs
2.1 kg / 4.6 lbs
0.8 kg / 1.8 lbs
1.2 kg / 2.7 lbs
25.5 kg / 56.2 lbs
WEIGHT
L70 mm (2.8”) W47 mm (1.9”)
H105 mm (4.1”)
L151 mm (5.9”) W35 mm (1.4”)
H102 mm (4”)
L151 mm (5.9”) W50 mm (2”)
H100 mm (3.9”)
L151 mm (5.9”) W50 mm (2”)
H100 mm (3.9”)
L298 mm (11.7”) W172 mm (6.8”)
H230 mm (9.1”)
6 V
6. 6-GRGS-200 200 220 30.5 kg / 67.2 lbs L323 mm (12.7”) W178 mm (7”)
H230 mm (9.1”)
DIMENSIONS
1. 12-HGRGS-7.2 12 V
(High Rate) 9 9.6 2.54 kg / 5.6 lbs L151 mm (5.9”) W65 mm (2.6”)
H102 mm (4”)
12 VOLT - HIGH RATE
RATED
VOLTAGE
BATTERY NAME RATED AH
10 HR RATE
RATED AH
20 HR RATE WEIGHT DIMENSIONS
GENERAL STORAGE RANGE - GRGS

|
10 CRYSTAL® BATTERY USER MANUAL
GENERAL STORAGE RANGE - GRGS
2.
3.
12-GRGS-10
12-GRGS-12
12-GRGS-7.21.
12 VOLT
10
12
12 V
12 V
12 V
12 V
12 V
12 V
12 V
12 V
12 V
12 V
12 V
12 V
12 V
12 V
12 V
12 V
12 V
12 V
12 V
12 V
7,2
5.
6.
7.
12-GRGS-18
12-GRGS-22
12-GRGS-24
12-GRGS-144.
22
24
14
18
9.
10.
11.
12-GRGS-28
12-GRGS-35
12-GRGS-40
12-GRGS-268.
35
40
26
28
13.
14.
15.
12-GRGS-65
12-GRGS-70
12-GRGS-90
12-GRGS-5512.
70
90
55
65
16. 12-GRGS-100 100
18.
19.
20.
12-GRGS-150
12-GRGS-180
12-GRGS-200
12-GRGS-12017.
180
200
120
150
RATED
VOLTAGE
BATTERY NAME RATED AH
10 HR RATE
12
13,2
7,8
24
27
15,5
20
40
44
29
32
78
100
60
72
110
190
220
132
162
RATED AH
20 HR RATE
3.5 kg / 7.7 lbs
4.1 kg / 9 lbs
2.2 kg / 4.6 lbs
6.9 kg / 15.2 lbs
7.8 kg / 17.2 lbs
4.25 kg / 9.4 lbs
5.9 kg / 13 lbs
12 kg / 26.5 lbs
13 kg / 28.7 lbs
7.8 kg / 17.2 lbs
8.5 kg / 18.7 lbs
22.3 kg / 49.2 lbs
27 kg / 59.5 lbs
16.9 kg / 37.3 lbs
21 kg / 46.3 lbs
31.5 kg / 69.5 lbs
59 kg / 130.1 lbs
62 kg / 136.7 lbs
36.5 kg / 80.5 lbs
46.5 kg / 102.5 lbs
WEIGHT
L151 mm (5.9”) W65 mm (2.6”)
H102 mm (4”)
L151 mm (5.9”) W99 mm (3.9”)
H102 mm (4”)
L151 mm (5.9”) W99 mm (3.9”)
H102 mm (4”)
L151 mm (5.9”) W99 mm (3.9”)
H105 mm (4.1”)
L181 mm (7.1”) W76 mm (3”)
H170 mm (6.7”)
L181 mm (7.1”) W76 mm (3”)
H170 mm (6.7”)
L175 mm (6.9”) W166 mm (6.5”)
H125 mm (4.9”)
L175 mm (6.9”) W166 mm (6.5”)
H125 mm (4.9”)
L175 mm (6.9”) W166 mm (6.5”)
H125 mm (4.9”)
L194 mm (7.6”) W132 mm (5.2”)
H176 mm (6.9”)
L196 mm (7.7”) W166 mm (6.5”)
H176 mm (6.9”)
L229 mm (9”) W138 mm (5.4”)
H215 mm (8.5”)
L350 mm (13.8”) W166 mm (6.5”)
H175 mm (6.9”)
L260 mm (10.2”) W169 mm (6.7”)
H215 mm (8.5”)
L307 mm (12.1”) W168 mm (6.6”)
H216 mm (8.5”)
L327 mm (12.9”) W172 mm (6.8”)
H220 mm (8.7”)
L407 mm (16”) W174 mm (6.9”)
H237 mm (9.3”)
L484 mm (19.1”) W170 mm (6.7”)
H241 mm (9.5”)
L522 mm (20.6”) W240 mm (9.5”)
H224 mm (8.8”)
L522 mm (20.6”) W240 mm (9.5”)
H224 mm (8.8”)
DIMENSIONS

|11
CRYSTAL® BATTERY USER MANUAL
FRONT TERMINAL RANGE - GRFT
LARGE STORAGE RANGE - GRLS
2.
3.
4.
12-GRFT-90
12-GRFT-100
12-GRFT-155
12-GRFT-551.
12 VOLT
100
155
12 V
12 V
12 V
12 V
12 V
12 V
55
90
6. 12-GRFT-180
12-GRFT-1705. 170
180
RATED
VOLTAGE
BATTERY NAME RATED AH
10 HR RATE
108
170
60
100
190
194
RATED AH
20 HR RATE
34.5 kg / 76.1 lbs
48 kg / 105.8 lbs
16.3 kg / 35.9 lbs
31.5 kg / 69.5 lbs
50 kg / 110.2 lbs
50.5 kg / 111.3 lbs
WEIGHT
L277 mm (10.9”) W106 mm (4.2”)
H228 mm (8.9”)
L396 mm (15.6”) W110 mm (4.3”)
H286 mm (11.3”)
L560 mm (22.1”) W125 mm (4.9”)
H228 mm (9”)
L558 mm (22”) W125 mm (4.9”)
H283 mm (11.14”)
L546 mm (21.5”) W125 mm (4.9”)
H320 mm (12.6”)
L546 mm (21.5”) W125 mm (4.9”)
H320 mm (12.6”)
DIMENSIONS
2.
3.
4.
2-GRLS-200
2-GRLS-300
2-GRLS-400
2-GRLS-100 1.
2 VOLT
300
400
2 V
2 V
2 V
2 V
2 V
2 V
2 V
2 V
2 V
2 V
2 V
2 V
100
200
6.
7.
8.
2-GRLS-600
2-GRLS-800
2-GRLS-1000
2-GRLS-500 5.
800
1000
500
600
10.
11.
12.
2-GRLS-2000
2-GRLS-2200
2-GRLS-3000
2-GRLS-1500 9.
2200
3000
1500
2000
RATED
VOLTAGE
BATTERY NAME RATED AH
10 HR RATE
330
440
108
220
880
1100
560
660
2420
3300
1650
2200
RATED AH
20 HR RATE
20.5 kg / 45.2 lbs
26 kg / 57.3 lbs
5.8 kg / 12.8 lbs
13.5 kg / 29.8 lbs
51 kg / 112.4 lbs
61 kg / 134.5 lbs
31 kg / 68.3 lbs
37.5 kg / 82.7 lbs
131.5 kg / 289.9 lbs
192 kg / 423.3 lbs
98.5 kg / 217.2 lbs
124 kg / 273.4 lbs
WEIGHT
L172 mm (6.8”) W72 mm (2.8”)
H210 mm (8.3”)
L174 mm (6.9”) W112 mm (4.4”)
H343 mm (13.5”)
L175 mm (6.9”) W155 mm (6.1”)
H365 mm (13.4”)
L210 mm (8.3”) W175 mm (6.9”)
H335 mm (13.2”)
L243 mm (9.6”) W175 mm (6.9”)
H338 mm (13.3”)
L301 mm (11.9”) W175 mm (6.9”)
H335 mm (13.2”)
L412 mm (16.2”) W175 mm (6.9”)
H337 mm (13.3”)
L480 mm (18.9”) W175 mm (6.9”)
H340 mm (13.4”)
L403 mm (15.9”) W354 mm (13.9”)
H350 mm (13.8”)
L491 mm (19.3”) W351 mm (13.8”)
H364 mm (14.3”)
L491 mm (19.3”) W351 mm (13.8”)
H364 mm (14.3”)
L712 mm (28”) W351 mm (13.8”)
H360 mm (14.2”)
DIMENSIONS

|
12 CRYSTAL® BATTERY USER MANUAL
the smooth passage of the gas while absorbing and
storing sufcient volumes of electrolytes to ensure
the batteries’ high performance. The oxygen can
rapidly distribute negative electrons to perform
cathode absorption and oxygen combination cycle.
SAM vs AGM
Standard AGM (Absorbent Glass Mat) is a material
used to function as a separator between plates that
assists in electrolyte distribution and furthermore
helps maintain the pasting oxide on the plates. As
AGM is comprised of glass bers, it tends to limit the
electron ow since glass is also an insulator. Our
advanced patented SAM is a super-absorbent mat
made entirely from non-insulating highly porous
organic bers, thus SAM has better electrolyte
absorption and has better retention compared to AGM.
2.1.5 Safety Valve
A safety exhaust valve is used that has high
sensitivity and can open or close according to the
internal pressure change of the battery. Safety valves
are made of corrosion-resistant anti-aging uorine
rubber and functions over the life of the battery to
retain the internal air pressure difference and retain
the moisture within the battery. The internal pressure
of the battery is maintained within an optimal safety
range.
* Green Rhino Crystal® batteries are extremely low
gassing batteries. See section 6.3.2 for more
information on gassing.
2.1.6 Sealing Performance
The battery compartment and covers are sealed with
rubber rings and the terminals are dual-sealed. An
epoxy resin sealing agent with low shrinkage is used
to ensure that the terminals and lids seal properly.
2.1.7 Plate Performance
The positive and negative plates are the core
electrochemical reaction region and the most
important components of the battery second to the
electrolyte. The grid is coated with lead paste and
formed after curing, drying, and other processes. The
active material of the positive and negative plates
has the following composition:
• Positive electrode plate: main component - Lead
Dioxide (PbO2);
• Negative electrode plate: main component -
Spongy Lead (Pb).
Crystal® batteries are a unique range of batteries
that were successfully developed by re-engineering
existing batteries and incorporating new patented
technologies. It has far better performance
characteristics when compared to conventional bat-
teries as a result of technological electro-chemical
breakthroughs. The fundamental issues of Lead Acid
battery like pollution, electrode sulphation, short life
cycle, poor low/high temperature performance, and
various other aws have been signicantly improved.
Green Rhino has set the highest standard for efcien-
cy, safety, long shelf and cycle life, along with excel-
lent product lifecycle and environmental credentials.
2.1 STRUCTURE CHARACTERISTICS
2.1.1 Special Electrolyte Composition
A unique and complex technology is used to synthe-
size a range of inorganic salts and various organic
substances, thereby optimizing the reaction between
the electrolyte and the active electrode material.
These salts effectively convert the active substance
into a Crystal® that prevents it from becoming brittle
and falling off the plates, thereby extending the
service life. After sufcient cycles, the electrolyte
within the battery crystallizes, leaving very little
free-owing electrolyte. This signicantly reduces
the chance of leakage which makes the battery safe
for transport and use. The battery may be installed
and used in a variety of orientations which simplies
system design and use. The wide range of installation
applications is possible since the risk of electrolyte
leakage is all but eliminated. The less corrosive
chemical reaction improves product safety making it
less harmful to installers and users alike.
2.1.2 Battery Enclosure
The battery enclosure is made from strong UL90 V2
ammability rated ABS plastic as a standard. It is
also available in a V0 and V1 ammability rating for
extreme temperature applications.
2.1.3 Grid and Plates
The grid is made with high-quality corrosion
resistant pure lead alloy (99.97% Lead) to ensure
excellent performance life of the positive and
negative grids. This improves the overpotential of the
anode and inhibits corrosion. Green Rhino Crystal®
batteries contain no Cadmium or Antimony further
improving the batteries’ eco-friendly status.
2.1.4 Separator - Super Absorbent Matt (SAM)
The patented separator is made of an ultra-ne
organic ber with enhanced saturation ability and
extreme porosity. By using cathode absorption
technology to create gas recombination, the SAM
separator has extreme acid resistance and stability,
which provides sufcient porosity and maintains
2. TECHNICAL SPECIFICATIONS

|13
CRYSTAL® BATTERY USER MANUAL
2.1.8 Special Manufacturing Process
Using negative pressure lling technology in combination with patented gravity lling containers to ll the
batteries with electrolyte and the patented terminal connecting equipment, ensures an even distribution of
electrolyte in each cell which further enhances the performance of the battery and increases efciency.
2.2 GENERIC WORKING PRINCIPLE
pbO2 +2H2SO4 + Pb + PbSO4
DISCHARGE
CHARGE
++ ++
PbSO4 + H2O
LEAD
DIOXIDE
POSITIVE
PLATE
ACTIVE
MATERIAL
DILUTE
SULPHORIC
ACID
LEAD
COMPOSITE NEGATIVE
PLATE
ELECTROLYTE NEGATIVE
PLATE
LEAD
SULPHATE
POSITIVE
DISCHARGE
MATERIAL
DISCHARGE
MATERIAL
WATER LEAD
SULPHATE
WATER NEGATIVE
Figure 1. The main electrochemical reaction during charge / discharge.
into active material when discharging, prolonging the
battery’s useful life and making it resistant to
sulphation.
Crystal® batteries use a new and patented advanced
type of super absorbent matt (SAM) as a separator.
The SAM has much higher electrical conductivity, heat
resistance, and acid resistance abilities than standard
commercial AGM separators.
The crystallized electrolyte in combination with the
SAM effectively protects the plates and prevents the
active material from falling off during regular use.
The electrolyte is completely absorbed and stored in
the SAM. Since the SAM is completely saturated with
electrolyte when crystalized, no free liquid electrolyte
will be present in the battery. The battery can now be
used in various directional positions without leaking.
CAUTIONARY NOTE: Long-term storage with the
plates horizontal to the ground may cause problems
in the longer term as vibration or gravity may
eventually reduce usage life.
The positive and negative active material reacts with
the acidic element of the electrolyte and becomes
lead sulphate and water when discharging, causing
the acid density to decrease. When charging, the acid
that concentrated in the positive oxide paste during
discharge cycles is released back into the electrolyte.
At this time, the lead sulphate in the positive and
negative plate transforms into lead dioxide and a
spongy type of lead which causes the acid density in
the electrolyte to increase. The patented
formulation acts to reduce the acidity of the solution
and in turn, increases the hydrogen concentration
that is required for ion exchange. None of the
condential chemical ingredients are indicated in
Figure 1 due to the sensitive nature and to
safeguard our intellectual property.
After charging or prior to charge completion, all the
charging current is used for electrolysis of the
moisture in the electrolyte with conventional
lead-based batteries. The positive plates release
oxygen and the negative plates release hydrogen gas.
If the gas recombination efciency of the battery is
low, a large percentage of the gas will escape
reducing moisture in the battery after every charge.
This action causes the electrolyte content to
decrease due to water loss which raises the acidity in
the battery and shortens the life of the battery. This is
known as late-charge uid-loss phenomenon.
With Crystal® batteries, the composite electrolyte has
various additives that participate in the electrochem-
ical reaction in addition to the regular chemical reac-
tion. The additives inhibit the oxygen and hydrogen
gas formation during the charging cycle increasing
the batteries’ recombination rate. This, in turn,
reduces the water loss during and after charging.
The lead sulphate can be totally transformed back

|
14 CRYSTAL® BATTERY USER MANUAL
3. CHARGE AND DISCHARGE SPECIFICATIONS
• Float (UPS) - Float Only
Requires full capacity discharge in a short period
of time once or twice a year.
The batteries are continuously in the oat phase
until required to discharge, in most cases a simple
charger is designed to only supply a oat
voltage/current and not have multiple phase
charge proles that are required for effective
battery charging. Float applications require a
deep discharge purication cycle, or equalization
cycle, at least every 3 months to ensure the
battery chemistry remains active and to prolong
the use life of the battery.
• High Cyclic - Bulk/Absorption with no or
infrequent oat
Requires a cyclic charge prole and more
frequent purication regime.
The batteries are frequently deeply discharged,
in most cases daily or in extreme cases multiple
times a day, in which charging consists of higher
voltage and current during the boost phase
followed by a reduced current absorption phase.
In extreme cases, the battery charge prole
seldom reaches the oat or top-up phase,
effectively forcing the battery to operate in a
partial state of charge.
When the application requires a partial state of
charge use, a purication charge MUST BE
performed weekly and in less demanding
applications, twice a month.
IMPORTANT NOTE: Float Applications
During oat/trickle charge applications, the
purpose is to replace the energy used by the internal
self-discharge chemical reactions to maintain it at
full charge. Generally, a power supply will deliver a
constant voltage between 13.5 volts and 13.7 volts
(typically 13.6 volts). This type of usage dictates that
a periodical purication charge must be performed
to maintain the batteries chemistry in a healthy state.
See section 3 for details on purication charge.
Due to the wide variations in oat charging systems,
we have provided charge specications in this manual
that will deliver the best possible results.
All lead-based batteries need to be put through the
three basic stages of charge BULK, ABSORPTION, and
FLOAT. If these stages are not achieved the battery
will NEVER be fully charged. If you intend to use
Crystal® batteries in a oat application, then we
encourage you to contact the Green Rhino technical
team to discuss the application, ensuring you achieve
the best results from the Crystal® batteries.
All batteries have different charge requirements due
to the variations of lead and alloys used to make the
plates, since the pasting density, composition, and
the electrolyte solution are critical to the battery
operation. Hence it is essential to be informed on the
charging requirements specied in the user manual
of the battery manufacturer.
In this chapter, the focus is on the minimum
requirements to charge a Crystal® battery, since it is
the single most important part of the batteries’ life
and how it will perform in systems. Additional type
and range specic charging and care information can
be found in the datasheets on the
www.greenrhino-energy.com website. Please take
special care to comply with recommendations since
the system performance and any warranty will be
subject to correct charging procedures.
Battery system applications are usually dened into
the following usage conditions:
• Cyclic - Regular Bulk/Absorption/Float
Requires the battery to deliver all or most of its
stored energy once per day over a long period of
time.
The batteries are discharged daily between 50%
and 80% Depth of Discharge (DoD), followed
by a full charge cycle. These charging cycles, as
mentioned above, must occur at the
recommended temperature-compensated voltage
and current during the bulk or boost phase,
followed by a reduced current absorption phase
that is then ended with a oat top-up phase at
a highly reduced charging current to ensure the
battery is fully charged and ready for the next
long discharge cycle.
• Standby - Float with the occasional Bulk/
Absorption/Float
Requires full capacity available for possible deep
cycle with less frequent discharges.
The batteries are less frequently discharged, 3
months or more between discharges, for
example, followed by a full charge as per the
cyclic use above. In most cases, this type of
application requires less frequent purication as
long as the charger is set to stop charging once
the battery is full or with pre-set timers that stop
the charging to prevent over-charging during
standby times

|15
CRYSTAL® BATTERY USER MANUAL
3.1 CHARGE CHARACTERISTICS GRGS, HGRGS, GRFT AND GRLS
Charge voltages must be temperature compensated and Bulk/Boost times need to be adjusted according to the
DOD to ensure optimal charge acceptance and enhance the recombination rate of the electrolyte.
This user manual should always be read in conjunction with the specic battery datasheet where further
charging/discharging information can be found. Always check to ensure you have the most recent version of the
datasheet and/or user manual by regularly visiting the Green Rhino website: www.greenrhino-energy.com
PLEASE OBSERVE THE FOLLOWING WHEN CHARGING CRYSTAL® BATTERIES:
• The voltages quoted in ALL the charging information are the required terminal voltages. You may need to
compensate your charger settings to overcome voltage drops over charging cables and other inline devices.
• When charging with a new charger always observe the battery during the rst few charge cycles to ensure
that the charger progresses through each stage of charge.
• Green Rhino always recommends new batteries be given at least 3 additional discharge/charge cycles before
putting new batteries into mission-critical applications.
• Crystal® batteries will typically increase by 5˚C (41˚F) to 10˚C (50˚F) during charging. If a battery is hot
during charge, it is recommended to perform a purication charge cycle and then re-observe the next charge
cycle. If the battery continues to get hot, consult the troubleshooting guide at the back of this
manual or consult a Green Rhino ofce.
• Always try and match the batteries from the sameproduction batch.
• Allow the batteries to cool down to room temperature after charging and prior to use for the best life and
discharge performance.
WARNING: FAILURE TO ADHERE TO RECOMMENDED CHARGE SPECIFICATIONS CAN REDUCE BATTERY
PERFORMANCE AND VOID YOUR WARRANTY IF THE BATTERY OVERCHARGES OR UNDERCHARGES.

|
16 CRYSTAL® BATTERY USER MANUAL
12-Volt Cyclic Charger Settings
Crystal® batteries are high-end pure lead battery products that work best with good quality battery chargers that
have the correct Crsytal® battery charge prole pre-loaded or that is custom programmable. See the below table
and the datasheet for charger settings for the 12-volt blocks.
WARNING: Discharging or charging a hot battery will reduce its life and increase the risk of overcharging.
3.1.1 GRGS, HGRGS, GRFT 12-Volt Cyclic Charge Specications
The above graph represents the correct charge prole for the 12-GRGS, 12-HGRGS, and 12-GRFT batteries and
indicates the minimum required charge curve for cyclic applications at an environmental temperature not
exceeding 25°C (77˚F).
Bulk/Boost phase charge with a constant voltage of 0.30C @ C10 (30% of the battery’s 10 hour rated capacity)
for 1 to 1.50 hours with a variable current until the battery voltage reaches the threshold 14.8 volts. Do not
exceed 3 hours charge time in the bulk/boost phase.
Absorption phase charge with a constant current of 0.15C @C10 (15% of the battery’s 10 hour rated capacity) for
3.5 hours with a variable voltage until the battery voltage reaches 14.8 volts. Do not exceed 5 hours charge time
in the absorption stage.
Float/Top up phase charge with a constant voltage of 13.7 volts and a variable current of 0.05C to 0.01C @C10
(5% down to 1% of the batteries 10 hour rated capacity).
12 VOLT BATTERIES 12-GRGS, 12-HGRGS AND 12-GRFT
CYCLIC /DAILY CYCLING APPLICATIONS
BULK / BOOST
Temperature
25˚C (77˚F)
35˚C (95˚F)
45˚C (113˚F)
* The above voltage set points are averages over indicated temperature ranges. Please refer to the technical datasheet for more specific voltage set points and temperature compensation for specific temperatures.
* The above set points are for voltage regulated multi stage IUoU and adjustable switch mode chargers.
0.3C
Minimum
(30% of C10
hour rated
capacity)
0.15C
(15% of C10
hour rated
capacity)
0.02C
(2% of C10
hour rated
capacity)
0.02C
(2% of C10
hour rated
capacity)
Max.
3 hours
Max.
5 hours Unlimited
13.6 Volts
13.4 Volts
13.4 Volts
14.7 Volts
14.5 Volts
14.2 Volts
14.7 Volts
14.5 Volts
14.2 Volts
Constant Current Variable Voltage Constant Current Variable Voltage Variable Current Constant Voltage
ABSORPTION FLOAT
Charge Capacity
C
harging
C
urrent
Charging Voltage

|17
CRYSTAL® BATTERY USER MANUAL
3.1.2 GRGS, HGRGS, GRFT 12-Volt Float Charge Specications
The above graph represents the correct charge prole for the 12-GRGS, 12-HGRGS, and 12-GRFT batteries and
indicates the minimum required charge curve for oat or standby applications with a maximum DOD of 80% to
1.8 volts per cell at an environmental temperature not exceeding 25°C (77˚F).
Bulk/Boost phase charge with a constant current of 0.10C @ C10 (10% of the battery’s 10 hour rated capacity)
for 6 hours with a variable voltage until the battery voltage reaches 13.7 volts. Do not exceed 7 hours charge
time in the bulk/boost phase.
Absorption/Float phase charge with a constant voltage of 13.7 volts and a variable current of 0.1C to 0.01C @
C10 (10% down to 1% of the batteries 10 hour rated capacity).
Green Rhino requires a periodical purication charge to be applied to the batteries when used in a FLOAT
application. See Section 3 for details on purication charging.
See the previous table and the datasheet for oat settings for the 12-volt blocks.

|
18 CRYSTAL® BATTERY USER MANUAL
6-Volt Cyclic Charger Settings
Crystal® batteries are high-end pure lead battery products that work best with good quality battery chargers that
have the correct Crsytal® battery charge prole pre-loaded or that is custom programmable. See the below table
and the datasheet for charger settings for the 6-volt blocks.
WARNING: Discharging or charging a hot battery will reduce its life and increase the risk of overcharging.
3.1.3 GRGS 6-Volt Cyclic Charge Specications
The above graph represents the correct charge prole for the 6-GRGS and batteries and indicates the minimum
required charge curve for cyclic applications with a maximum DOD of 50% (down to 2 volts per cell) at an
environmental temperature not exceeding 25°C (77˚C).
Bulk/Boost phase charge with a constant voltage of 0.30C @C10 (30% of the battery’s 10 hour rated capacity)
for 1 to 1.50 hours with a variable current until the battery voltage reaches 7.4 volts. Do not exceed 3 hours of
charge time in the bulk/boost phase.
Absorption phase charge with a constant current of 0.15C @C10 (15% of the battery’s 10 hour rated capacity) for
3.5 hours with a variable voltage until the battery voltage reaches 7.4 volts. Do not exceed 5 hours charge time
in the absorption stage.
Float/Top up phase charge with a constant voltage of 6.85 volts and a variable current of 0.05C to 0.01C @C10
(5% down to 1% of the batteries 10 hour rated capacity).
6 VOLT BATTERIES 6-GRGS
CYCLIC /DAILY CYCLING APPLICATIONS
BULK / BOOST
Temperature
25˚C (77˚F)
35˚C (95˚F)
45˚C (113˚F)
* The above voltage set points are averages over indicated temperature ranges. Please refer to the technical datasheet for more specific voltage set points and temperature compensation for specific temperatures.
* The above set points are for voltage regulated multi stage IUotU and adjustable switch mode chargers.
0.3C
Minimum
(30% of C10
hour rated
capacity)
0.15C
(15% of C10
hour rated
capacity)
0.02C
(2% of C10
hour rated
capacity)
0.02C
(2% of C10
hour rated
capacity)
Max.
3 hours
Max.
5 hours Unlimited
7.35 Volts
7.25 Volts
7.10 Volts
7.35 Volts
7.25 Volts
7.10 Volts
6.80 Volts
6.70 Volts
6.70 Volts
Constant Current Variable Voltage Constant Current Variable Voltage Variable Current Constant Voltage
ABSORPTION FLOAT
Charge Capacity
C
harging
C
urrent
Charging Voltage

|19
CRYSTAL® BATTERY USER MANUAL
3.1.4 GRGS 6-Volt Float Charge Specications
The above graph represents the correct charge prole for the 6-GRGS batteries and indicates the minimum
required charge curve for oat or standby applications with a maximum DOD of 80% (to 1.833 volts per cell) at
an environmental temperature not exceeding 25°C (77˚F).
Bulk/Boost phase charge with a constant current of 0.10C @C10 (10% of the battery’s 10 hour rated capacity) for
6 hours with a variable voltage until the battery voltage reaches 6.85 volts. Do not exceed 7 hours charge time in
the bulk/boost phase.
Absorption/Float phase charge with a constant voltage of 6.85 volts and a variable current of 0.1C to 0.01C @
C10 (10% down to 1% of the batteries 10 hour rated capacity).
Green Rhino requires a periodical purication charge to be applied to the batteries when used in a oat
application. See Section 3 for details on purication charging.
See the previous table and the datasheet for oat settings for the 6-volt blocks.

|
20 CRYSTAL® BATTERY USER MANUAL
2-Volt Cyclic Charger Settings
Crystal® batteries are high-end pure lead battery products that work best with good quality battery chargers that
have the correct Crsytal® battery charge prole pre-loaded or that is custom programmable. See the below table
and the datasheet for charger settings for the 2-volt blocks.
WARNING: Discharging or charging a hot battery will reduce its life and increase the risk of overcharging.
3.1.5 GRLS 2-Volt Cyclic Charge Specications
The above graph represents the correct charge prole for the 2V GRLS batteries and indicates the minimum
required charge curve for cyclic applications with a maximum DOD of 50% (down to 2 volts per cell) at an
environmental temperature not exceeding 25°C.
Bulk/Boost phase charge with a constant voltage of 0.30C @C10 (30% of the battery’s 10 hour rated capacity)
for 1 to 1.50 hours with a variable current until the battery voltage reaches 2.47 volts per cell. Do not exceed 3
hours charge time in the bulk/boost phase.
Absorption phase charge with a constant current of 0.15C @C10 (15% of the battery’s 10 hour rated capacity)
for 3.5 hours with a variable voltage until the battery voltage reaches 2.466 volts per cell. Do not exceed 5 hours
charge time in the absorption stage.
Float/Top up phase charge with a constant voltage of 2.28 volts and a variable current of 0.05C to 0.01C @C10
(5% down to 1% of the batteries 10 hour rated capacity).
2 VOLT BATTERIES 2-GRLS
CYCLIC /DAILY CYCLING APPLICATIONS
BULK / BOOST
Temperature
* The above voltage set points are averages over indicated temperature ranges. Please refer to the technical datasheet for more specific voltage set points and temperature compensation for specific temperatures.
* The above set points are for voltage regulated multi stage IUoU and adjustable switch mode chargers.
0.3C
Minimum
(30% of C10
hour rated
capacity)
0.15C
(15% of C10
hour rated
capacity)
0.02C
(2% of C10
hour rated
capacity)
0.02C
(2% of C10
hour rated
capacity)
Max.
3 hours
Max.
5 hours Unlimited
2.45 volts
2.41 volts
2.37 volts
2.45 volts
2.41 volts
2.37 volts
2.27 volts
2.24 volts
2.23 volts
Constant Current Variable Voltage Constant Current Variable Voltage Variable Current Constant Voltage
ABSORPTION FLOAT
25˚C (77˚F)
35˚C (95˚F)
45˚C (113˚F)
Charge Capacity
C
harging
C
urrent
Charging Voltage