Kaise OPZV Series User manual

OPZV SERIES TUBULAR GEL BATTERY
OPERATION MANUAL
Version 1.1

Contents
SECURITY INSTRUCTIONS................................................................................................. 1
PART ONE PRODUCT INTRODUCTION......................................................................... 2
1. Construction.................................................................................................................2
2. Product Specifications............................................................................................... 2
3. Working Principle........................................................................................................ 3
PART TWO OPERATION AND MAINTENANCE............................................................. 4
1. Operation Condition................................................................................................... 4
2. Capacity....................................................................................................................... 4
3 Temperature..................................................................................................................5
4 Charge and discharge requirements........................................................................ 7
5 Storage........................................................................................................................ 10
6 Maintenance............................................................................................................... 10
PART THREE BATTERY INSTALLATION...................................................................... 14
1 Unpacking and Inspection........................................................................................ 14
2 Installation Precautions.............................................................................................14
3 Installation and Wiring...............................................................................................14

1
Security Instructions
Please read this manual! It provides very important information for security, installation,
operation, which can make best capability for the equipment, and elongate the using life.
Do not try to take apart batteries. The spare parts are not inside the battery. Maintenance
works should be done by professionals.
As a result of the battery’s latent danger to health and environment, they should be only
changed in authorized service center. If you need to change the battery or maintain the
equipment, please call the nearest service center.
Batteries can be reclaimed, if it could not be carefully handled, it would bring a lot of
dangers to environment and health. Please check laws to get the valid ways or send the
equipment to service center.
The replacement should be made or supervised by professionals with suitable protection.
The batteries for replacement should be used as the same as the old ones in model and
type.
Warning——Do not smoke or use fire near batteries.
Warning——Do not use any organic cleanser to clean batteries.
Warning——Do not put the batteries on fire, or they will explode.
Warning——Do not cut open the batteries. They contain electrolyte which is toxic to skin
and eyes.
Warning——Batteries may cause shock and short. Please remove the watch and jewelry
such as rings when replacing the batteries. Also please operate with insulating tools.
Warning——Tightening the screws, otherwise there will be spark and heat while closing
the circuit, this may cause battery burnt. The F-M6 terminal torque is 6～8N.m, The F-M8
terminal torque is 10～12N.m.
Please take care of the following marks during operation
Symbol
Explain
Symbol
Explain
Symbol
Explain
Warning
Electricity
danger
Protecting
your eyes
Watch
Short-circuits
With adults
custody
Read the
manual
Fire forbidden
Recycle use
Do not put
batteries into
dustbin
Pass CE
Safety
authentication
Handle with
care

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2
Part one Product Introduction
1. Construction
Battery lid, container
Made of reinforce ABS plastic with sufficient strength and acid-resistance ability, to prevent
leakage of electrolyte and gas
Terminal
With tin-coated red copper insert to reduce internal resistance, and with good conductivity

PVC-SiO
2
separator
With high oxygenation-resistance and heat-proof ability, and electrolyte can be well absorbed and
retained in the separator
Positive and negative plate
Made of Pb-Ca-Sn alloy tubular positive grid and flat negative grid and special formula active
material

Valve
Made of acid-proof, aging-proof synthetic rubber

Flame arrestor
With acid-proof, explosive-proof functions
2. Product Specifications
M
odel Nominal
Voltage (V)
Capacity
(Ah)@10hr
Dimension (mm) Weight
(kg)
Length
Width
Height
Total Height
4
OPzV200 2 200 103 206 354 390 17.3
5
OPzV250 2 250 124 206 354 390 20.7
6
OPzV300 2 300 145 206 354 390 24.4
5
OPzV350 2 350 124 206 471 506 27.5
6
OPzV420 2 420 145 206 471 506 32.5
7
OPzV500 2 500 166 206 471 506 37.3
6
OPzV600 2 600 145 206 646 681 44.2
8
OPzV800 2 800 191 210 646 681 60
1
0OPzV1000 2 1000 233 210 646 681 71.5
1
2OPzV1200 2 1200 275 210 646 681 87
1
2OPzV1500 2 1500 275 210 796 831 107
1
6OPzV2000 2 2000 399 212 772 807 147
2
0OPzV2500 2 2500 487 212 772 807 185
2
4OPzV3000 2 3000 576 212 772 807 216

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3
3. Working Principle
The chemical reactions take place in lead acid battery is as follows:
Pb+PbO2+2H2SO42PbSO4+2H2O
Following by-reaction ①takes place in ordinary lead acid battery:
2H2O 2H2↑+O2↑①
2Pb +O22PbO ②
PbO + H2SO4PbSO4+H2O③
OPzV Battery adopt gel electrolyte and PVC-SiO2Separator to set up oxygen cycle principle:
Battery is full of gel electrolyte inside, and A 3-D porous network is formed with framework of SiO2.
The net contains electrolyte necessary for battery. At initial stage, the construction is not steady. As
time goes on, the framework is shrink and some cracks appeared in the gel. The cracks exist
between pos.& neg. plates and separator and become a path between the positive and the
negative. Thus it is possible to build GEL battery in sealed structure.
discharge
charge

OPzV Battery Operation Manual
4
Part two Operation and Maintenance
1. Operation Condition
1.1 The recommended operating temperature range for optimum life and performance is from
15 ℃to 25 ℃.
If the battery is used at high or low temperature, it will affect battery performance.
1.2 Max Operating Temperature Range:
GEL batteries：
Charge -20～+55℃;
Discharge -40～+60℃;
Storage -20～+45℃;
1.3 Humidity: ≤95%
1.4 Ventilation requirements:
During normal charging conditions the volume of hydrogen emitted from a Kaise VRLA / Gel
battery is virtually negligible, and will normally dissipate rapidly into the atmosphere. The room or
cabinet ventilation should comply with standard EN 50272-2: 2001.
2. Capacity
2.1 Concept of 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.
Normally we indicate discharge hours rate in lower corner of C. e.g. C10 is 10 hours rated capacity,
and C3is 3 hours rated capacity.
The capacity can be expressed in Rated Capacity or Actual Capacity. The Rated Capacity
please sees Table 1-1. The Actual Capacity is the product of the discharge current and the
discharge time, the unit is AH.
The way to determine capacity: e.g. when we try to determine 10 hours rated capacity, please
discharge with current of I10 for 10 hours, if the voltage of battery is larger than 1.80Vpc, it means
10 hours rated capacity is qualified.
2.2 The Influence Factor of the Actual Capacity
The actual capacity is mainly related with the positive and negative active materials and their
utilization ratio. The utilization ratio of the materials is mainly influenced by the discharge system,
the structure of the battery and manufacture technology. In operation process, the factors that
influence the actual capacity are discharge rate, discharge system, end voltage and temperature.
2.3 Discharge Rate
The discharge rate is often described as hour-rate and multiple rates.
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.
2.4 End voltage
The end voltage is the lowest working voltage below which the battery can’t be discharged

OPzV Battery Operation Manual
5
any more or it will harm the battery. Usually the 10hr rate end voltage of battery is 1.80V/cell, and
the 20hr rate end voltage of battery is 1.80V/cell.The batteries are not able to discharge more
capacity even if the end voltage is lower because of characteristics of lead acid battery, yet the low
end voltage makes great harm to the battery. It will greatly shorten batteries’ life especially to
discharge the battery to 0V while not to recharge in time. Thus the end voltage should not be lower
than what is described in table 3-2, or it will cause over-discharge and make battery failure after
several times of over-discharge.
Table 3-2 Discharge End-voltage
Discharge Current（A）Discharge End Voltage (V/cell)
I <0.08C ≥1.85
0.08C≤I <0.2C
≥1.80
0.2C≤I <0.6C ≥1.75
0.6C≤I <1.0C
≥1.70
1C≤I <2C ≥1.60
3 Temperature
3.1 Available Capacity vs. Ambient Temperature
Temperature affects capacity of the battery. Fig. 3-1 is the available capacity curve vs.
ambient temperature. If the temperature drops, the capacity will decrease, for example, the
capacity will decrease to 80% of rated capacity if temperature decreases from 25℃to 10℃; and
too low temperature will cause battery long term insufficient charged, also will cause no discharge
and negative plates sulfate.
Though VRLA battery can be operated at -20℃, the standard data is the test result at 25℃.
The capacity will increase when temperature rises. For example the capacity will increase to
102% of rated capacity if temperature increases from 25℃to 50℃. But the capacity increase very
little when temperature goes on increasing, and it will stop increase at last. However, it will quicken
plates’ corrosion and water loss if temperature rises, and shorten battery’s life.

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Fig.3-1 Available Capacity vs. Ambient Temperature
3.2 Temperature and Floating Voltage
The purpose of choosing proper floating voltage is to make the battery operate in a best
condition. If the floating voltage is higher, and then the floating current is also higher, it will
accelerate corrosion of the grid and shorten life of the battery. If the floating voltage is lower, the
battery can’t be kept in fully charged state; this will cause sulfate, decrease the capacity, and also
shorten the life of the battery.
Table 3-3 is floating voltage of VRLA battery at 25℃. And temperature compensation
coefficient is -3Mv/℃/cell
Table 3-3 Floating Voltage of VRLA Battery（25℃）
Series
Floating voltage
（
V/cell
）
OPzV
2.23
±
0.02
The formula to calculate float voltage at different temperatures:
VT= V25 - (T-25)×0.003
VT—Floating charge voltage at T temperature
V25—Floating charge voltage at 25℃,
When the float voltage is lower than 2.20V/cell or higher than 2.30V/cell after being adjusted
by temperature compensation coefficient, we suggest stopping making temperature
compensate and charge the battery with 2.20V/cell or 2.30V/cell.
3.3 Temperature and equalization charge
VRLA battery needs equalization charge periodically to guarantee normal operation. Table 3-4
is equalization voltage of VRLA battery at 25℃. And temperature compensation coefficient is
-5mV/℃/cell.

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Table 3-4 equalization charge of VRLA battery(25℃)
Series
Equalization charge
（
V/cell
）
OPzV
2.35
The formula to calculate equalization voltage at different temperature:
VT= V25-(T-25)×0.005
VT—Equalization charge voltage at T temperature
V25—equalization charge voltage at 25℃,
When the boost voltage is lower than 2.30V/cell or higher than 2.45V/cell after being adjusted
by temperature compensation coefficient, we suggest to stop making temperature compensate
and charge the battery with 2.30V/cell or 2.45V/cell.
3.4 Ambient Temperature vs. Battery Life
Higher temperature will harm the battery and reduce battery life. When temperature exceeds
25℃, the battery life will decrease half per 10℃temperature rises. For example, the designed life
of battery at 25℃is 10 years, when battery operates at 35℃, for a long period of time the actual
life is only 5 years.
t25＝tT×2（T－25）/10
Notes：T is the actual ambient temperature;
tTis designed life at T ambient temperature
t25 is designed life at 25℃ambient temperature
The heat disseminates performance of VRLA battery is bad, it’s liable to cause thermal run
away when heat accumulates. Please improve ventilation and temperature condition when room
temperature is high. The distances between batteries should not be smaller than 10mm. Please
also adjust the float voltage and equalization voltage according to the manual.
4Charge and discharge requirements
4.1 Equalization charge
Equalization charge is needed in following conditions:
a The floating voltage of at least two batteries are lower than 2.16V/cell;
b Floating operation is more than three months.
The method of equalization charge is: First charge the batteries with the constant current of
0.1C10A～0.15C10A till the average voltage of the batteries increases to 2.35V/cell(25℃)，then
charge the batteries with constant voltage of 2.35V/cell, the time of equalization charge is 24
hours.
4.2 Charge after discharge
The batteries need to be charged in time after discharge. The charge method is constant
current and limited voltage charge: Charge the batteries with constant current of 0.1C10A～0.2C10A
till the average voltage of the batteries increases to a certain voltage, then charge the batteries
with this constant voltage till finishing charge, meanwhile the current will reduce.

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The certain voltage can be equalizing voltage or floating voltage. When the discharge depth is
large (such as larger than 10% C10), equalizing voltage is recommended, which will make charging
more sufficient. We can also determine the voltage according to initial current. When current is
large than 0.05C10A (the reference current when transfer to equalizing charge), we recommend
equalizing charge. the time of charge is 24 hours. Or the value of charge current is not varied for
continuous three hours under the condition of constant voltage, we can determine the charge is
finished.
We can raise charge current if batteries need to be fully charged in a short time, but the
current cannot be higher than 0.25C10A.
4.3 Battery Recharging Method
This method is used for battery charging for the first time after installing or battery recharging
after long time storage.
Recharging Parameter
We use equalizing charge to recharge the batteries, the parameter is as below:
1
Charging mode: equalizing charge;
Charging voltage: 2.35V/cell, for -48V system, charging voltage is 56.4V;
Charging voltage (made up with 2V cell) = 2.35 × 1× battery quantity
2
Current limited: 0.10C
10
(A);
3
Cut-off condition: the charging current is less than 0.005C10 with another extended 3
hours or charging time reached 16 hours;
Recharging Procedure
1
Connect the batteries in series with cables or copper bars, and make sure that all the
screws tightened with each joint, then connect the positive of battery group to the positive of
charging equipment (charger), and the negative of battery group to the negative of charger. Pay
attention, a breaker or fuse should be connected in the circuit in order to protect the batteries and
charger, the capacity of breaker or fuse should be 1.5 times of circuit maximum current.
2
Turn on the charger, set the charging voltage and current according to 3.1 Recharging
Parameter.
3
Turn on the breaker or fuse, and then turn on the charger to recharging batteries.
4
Stop charging when reaching the cut-off condition. At the last one hour before finishing,
test the battery voltage one by one, the battery which voltage is below 2.16V/cell should be dealt
with the method in chapter 3.3, if that battery still can not accord with the requirement, it should be
rejected.

Cycle Procedure
We can use the method as below to recharge the batteries after long time storage (for
example: more than 1 year):
First connect the batteries in series to the charger, discharge batteries with constant
current 0.25C10 (A) for about 3 hours. Then use the method in chapter 3.2 to charge the
batteries. Stop charging when reach the cut-off condition
If the capacity still can not be renewed by this method, this means the batteries fail
because of long time storage or other reasons.