RITAR DG Series User manual

Technical Manual
DG SERIES VALVE REGULATED LEAD-ACID BATTERY

Item Page
Prolegomenon
1 Application Range
2 Check
3 Storage before Installation
4 Installation Cautions
5 Battery Features
6 Operating Principle
7 Battery Charge, Discharge & Life
8 Record
9 Maintenance
10 Common Faults & Solutions
1
1
1
1
2
2
3
4
7
7
8
Contents

Prolegomenon
In order to use Ritar GEL series battery correctly and safely, please read this technical manual and
other data together with battery carefully for a comprehensive understanding.
★Pay attention to safety during installation to avoid accident.
★It is required for users to read this manual carefully and keep it well.
★If you have any questions about the Technical Manual or any technical problems, please contact us or our local agent.
Dangerous!
High Voltage……
Don't touch any terminals or connectors
without insulation to avoid electric shock.
Eyes Protection:
Gas from explosion may harm eyes
or even cause blindness.
Prohibition:
Sparks, fire and
smoking.
Vitriol:
May cause blindness
or severe burns.
Wash eyes with clean water
immediately and go to see
a doctor.
Do not loosen the safety vales.
Please read carefully the installing and using instructions in this manual.
Keep the battery in a well ventilated environment when in operation.
Battery maintenance and repair should be conducted by experienced technicians.
1Application Range
This manual is applied to Ritar Nano Silicon GEL Deep Cycle series battery (hereafter referred to as battery).
2Check
1. Af ter rec ei vi ng the bat ter ies , pl eas e check the pac king and mak e su re the bat teries ar e int ac t. Avo id bumpi ng
dur ing carryi ng, and be ca reful when ope n the cartons .
2．Pleas e ope n the ca rtons nea r the ins tal lation pl ac e and ch ec k app ear anc e and qua ntity of the bat tery accessories
after ope ni ng .
3．It's di fficult to det ect leak age if ther e ar e sl ight damages on the bat tery shell. Pl eas e check carefully and mak e
sure ther e is no damage or leak age on the bat ter y sh el l.
4 . If the bat ter y fal ls to the gr oun d or its sh el l is bumped abn or mally, pl eas e repo rt the det ai ls to our compan y for
confirmat ion and af ter mat h ar rang ement .
3Storage before Installation
1． Storage Environment
If the battery is not installed immediately after being received, please store it in a clean, ventilated
and dark place at around 5~30℃.
2． Storage Time
Due to self-discharge, the battery capacity will lose gradually in storage. Do not store the battery
over 12 months or it will affect the battery performance eternally. After being stored for 6 months,
the battery should be charged in voltage of 2.40 ± 0.1V for 24 hours and hereafter should be
recharged at regular intervals ( at least once every 6 months). A relatively high temperature will
accelerate the battery self-discharge; from 20℃ when the temperature increases every 10℃,
recharging interval should be reduced half. For example, when the battery is stored at 35℃,
its initial charging or recharging interval should be 3 months.
If the battery is not charged properly, its performance and life will be affected and cause the normal
guarantee invalid.

4Installation Cautions
1． Before touching the battery, please wear a rubber apron, rubber gloves, safety goggles
or other eyes protection equipments; do not wear metal objects, such as jewelry etc.
2．The battery is very heavy. Be careful and do not pump the battery when moving it.
3． Smoking or lighting fires are strictly forbidden. Keep the battery away from electric arc.
4．Avoid short circuit. The battery has been charged and please prevent battery from short
circuit to avoid equipment damage or personal injury.
5．Put the battery in a cool and well ventilated place. Do not install the battery in a place
that is possible to be immersed by water.
6．Fix the bolts and nuts on the connection terminals to the specified torque; otherwise it
may cause sparks or damages to the terminals.
7．Please clean the battery shell and cover with a wet cloth; to prevent static and spark,
do not use a duster or a dry cloth to clean the battery. It's prohibited to use organic
solvent such as rubber solution or naphtha, which will cause the battery shell cracking.
8．In normal operation, there will be no dissociative electrolyte attached on the shell after
battery gets fully sealed. However, if the battery shell is damaged, dissociative vitriol is
possible to leak. In case electrolyte splashes onto eyes, skin or clothes, flush it with a
large quantity of water. If it splashes into eyes, after rinsing with water, please go to see
a doctor promptly.
9．Make sure the positive （+/red） and negative（-/black）terminals are connected
properly, otherwise it will cause fire or damages to the battery or charger.
10. Please use the following protection equipments when you carry, install and maintain the
battery.
1）Safety goggles or protective face-shield;
2）Acid-resistant gloves;
3）Acid-resistant apron, safety shoes;
4）Proper carrying instruments;
5）Insulation instruments.
11．Battery posts, terminals and fittings contain lead or lead compound; and other chemical
compositions in the battery are harmful to personal health.
Wash your hands after touching the battery!
Battery Features
5
1. Long Service Life
Heavy duty lead-calcium grids ensure mild corrosion and enable a long designed service life
over 10 years standby use under optimal float charge conditions and below optimal operating
temperature of .
2.Patent Designed Construction
RITAR batteries are equipped with PE compound separator construction, which ensures that
gel electrolyte is distributed evenly through-out the inner battery and ensures the best evenness
of all parts of the battery.
o
25 C
2

6
3.Triplex Sealed Construction
Valve regulated sealed construction and triplex strengthened sealing on terminals and posts
prevent electrolyte leakage, and guarantee the air tight and liquid tight state of batteries in
normal operation and prevent external air from entering battery inner.
4.Low Self Discharge
Because of the use of lead-calcium grids alloy, RITAR batteries have low self discharge and
reliable performance. In room temperature, self discharge ratio per month of RITAR battery is
about 3% of the battery capacity.
5.High Security
RITAR batteries are equipped with explosion-proof safety valves to prevent production of
redundant gas. And the construction is designed to prevent setting fire to the internal battery in
case sparkles approach.
6.High Efficiency of Recovery
Unique formulas are used in lead paste of positive post and ensure the battery can be recharged
easily to a normal level.
7.No Electrolyte Stratification
Special additives are use in electrolyte to give it a gelatinous consistency without flowing, leaking
or stratification, and make all parts of plates react evenly.
Operating Principle
1.Electrochemistry
A lead-acid battery is an electrical storage device
that converts electrical energy into potential
chemical energy; when needed the stored
chemical energy can be converted back into
electrical energy again to be supplied to
external systems. In the discharge sta te,
part of at the positive turns into ,
and part of Pb at the negative also turns into
. In this electro-chemical reaction, both
positive and negative electrodes generate
. In the charging state, the lead sulfate
( ) at the positive and negative turns into
and Pb, respectively. When in discharging,
the concentration and density of electrolyte
decreases gradually; while in charging,
it increases. Battery charging and discharging
are realized by electrochemical reactions.
PbO PbSO
2 4
PbSO4
PbSO4
PbSO4
PbO2
H SO
2 4
Positive: PbSO + 2H O
4 2
Charge
Discharge
Charge
Charge
Charge
Discharge
Subsidiary Reaction: H O
2
Subsidiary Reaction: +
2H+2e
+
Negative: PbSO +2H+2e
4
3

0.04
0.08
0.1 2
0.1 6
0.2 0
0.2 4
0.2 8
2.6 0
2.4 0
2.2 0
2.0
1.8
1.6
2.4 2
2.3 6
0.3 0
0.2 4
0.1 8
0.1 2
0.0 6
2.Oxygen Combination
The pos itive plate generat es oxy ge n gas in the final
stage of char g i n g . Un d e r th e c o n d i t i o n o f ex c e s s i v e
a d d i t i v e s a t t h e n e g a t i v e , o x y g e n s p r e a d s t o t h e
negat ive pl at es through PE com pound separ at or and react s with
s p o n g y l e a d a n d f o r m s l e a d o x i d e a n d t h e n t u r n s
into lead sulfate and wa ter. Keep the negative plates
i n d e p o l a r i z a t i o n o r u n d e r c h a r g e s t a t e s o t h a t t h e
b a t t e r y c a n n o t r e a c h t h e o v e r p o t e n t i a l o f o x y g e n
g a s s i n g . T h u s t h e b a t t e r y a v o i d s o x y g e n g a s s i n g
and wat er loss and is made a maintenance free seal ed
storage bat ter y.
7 Battery Charge, Discharge & Life
1. Charge Characteristics
Charge condition is one of the important factors in
battery use. The battery performance and service
life are directly related to its charging methods
and charging parameters in using. The battery is
recommended to be charged at the temperature
range of 5-30℃ . At any temperature lower than 5℃
or higher than 35℃it will cause undercharge or
overheating and then decrease the battery life.
2. Charge Curve of Float Use
3. Relationship between Float Charge Voltage and Environment Temperature
At general temperature （5℃~30℃ ）, float charge voltage is 2.25V~2.30V. The batteries for float
charge service adopt the constant voltage but limited current method. The initial current is
0.1 and the maximum current is 0.2 .
1) At 25℃, the float charge voltage of battery is 2.27V per cell.
2) When the ambient temperature changes, the float charge voltage should be adjusted. The
temperature compensation coefficient is -3Mv/, i.e., Ufloat=「2.27 – 0.003(t-25)」* n.
C A C A
2o 20
5. Charge Curve of Cycle Use
The batteries for cycle service adopt the constant
voltage but limited current method. At 20℃~25℃,
the charge voltage of GEL series battery is 2.40V
per cell; the initial charge current is not larger than
0.2 and the battery fully charges in approximately
24 hours.
C A
20
In the final stage of charging, if the charge current
value remains unchanged for 3 hours, it indicates
that the battery is fully charged.
Charge curves are as right.
Positive
Negative
Charge Overcharge
Charge
Charge Characteristic Curve of Float Use
Charge Volume (%)
Charge Current (A)
Charge Voltage (V)
Charge Time (Hr)
Charge Voltage
Charge Volume
Discharge
Charge with
& Limited Curre nt :
Charge Voltage : 2.30V/Cell
Charge Curren t: 0.2
Constant Volta ge
C A
20
Temperature: 25℃/77℉
Charge Characteristic Curve of Cycle Use
Charge Volume (%)
Charge Current (A)
Charge Voltage (V)
Charge Voltage
Charge Volume
Discharge
Charge with
& Limited Curre nt :
Charge Voltage : 2.40V/Cell
Charge Curren t: 0.2
Constant Volta ge
C A
20
Temperature: 25℃/77℉
Charge Time (Hr)
20
20
4
Equalize charge is required for float Service as long time float charge will make some batteries drop
behind in the battery bank. An equalize charge can prevent battery stratification and reduce
sulfation and bring all cells to similar levels, which is the leading cause of battery failure.
Equalize charge requirements for RITAR battery as follows:
※ Equalize charge 1 time every three months or every 20 discharge cycles.
※ Equalize charge method: with equalize charge voltage 2.35~2.45Vpc @25℃ and max. charge
current 0.3CA, and equalize charge time is 12~24h(when the charge current at the end stable about
2~3 hours ,stopped equalize and switch to float ).
※ Before equalize charge please let the battery 100% discharged.
4. Equalize Charge

Storage Time (Month)Charge Voltage (V/Cell)Maximum Charge Current(A)Charge Time(Hr)
3
~
6
6
~
12
2.40
2.40
0.2C2 0
0.2C2 0
24
36
6. Supplementary Charging
Due to self discharge, battery stocked longtime,
the capacity reduce slowly, the relationship
between capacity reservation, temperature and
stock time as right curves.
Supplementary Charging adopts the constant
v o l t a g e but l i m i t e d c u r r e n t m e t h o d .
charging current is 0.05 – 0.2 ,
charging voltage is 2.35 ± 0.05V/Cell, generally
charge for 24~36 hours. After longtime storage,
before use, battery should be makeup charged.
Generally C C
20 20
7. Discharge Characteristic
Discharge rate is different, the cutoff voltage also
different. Higher discharge current, lower cutoff
voltage; reversely, lower discharge current, higher
cutoff voltage. Normally the battery cutoff voltage
set at 1.80 – 1.60V. The discharged capacity is
lower with higher discharge current.
Discharge characteristic curves are as right:
Discharge Capacity vs Temperature
Battery discharge capacity is related with temperature. Lower temperature, lower capacity
discharged; higher temperature, higher capacity discharged. But the too high temperature will
seriously damage the battery lifetime. The best working temperature for battery is 20- 25 .
The discharged capacity at different temperature Ct vs Discharged capacity at 25 C25
have below relationship:
℃
℃
Surplus Capacity (%)
Capacity Reservation Curves
No need of supple mentary
charg in g. Used in flo at
charg e.
Supple mentary Chargin g
is required.
Supple mentary Charging
performance will be affected.
It is prohibited to leave
the battery standing
till this state.
Storage Time (Month)
Storage Time vs Charge Voltage and Charge Time
Discharge Characteristic Curves
Termial Voltage (V)
6.5
6.0
5.5
5.0
4.5
13
12
11
10
9
4.3
4.0
3.7
3.3
3.0
0.6 1.2 3 6 1 2 3 0 1 2 5 10 20 24
Min Hr
3C 1C
0.6 2 C 0.35C
0.16C 0.093C
0.05C
5

Temperature vs Capacity Curve
12 0
11 0
10 0
80
60
40
0-40 -30 -20 -10 -0 10 20 30 4 0 50 Temperature
（℃）
Effective Capacity (%)
Float Life Characteristic Curves
20 30 40 50 C
68 8 6 104 122 F Temperature
20
16
10
14
8
6
4
5
3
2
1.4
1
Life(Year)
Float Charge
Voltage(V)
2. 3 0 1 5 . 0 1 0 . 6 7 . 5 3. 7 1. 9
20 C 25C 30C 4 0 C 50 C
Battery Actual Float Life at Different Temperature (Year)
20Hr rate discharge：K=0.006/℃；5Hr ：K=0.007/℃rate discharge
3Hr ：K=0.008/℃；1Hr ：K=0.010/℃rate discharge rate discharge
C25 Discharged capacity at 25 (AH)
Ct Discharged capacity at t℃ (AH)
t Environment temperature during discharge (℃)
K Temperature compensation coefficient
℃
Temperature vs Capacity Curves as below:
8. Float Life Characteristic
At recommended float charging situation at 25 , GEL battery design life is over 10 years. Battery's
usage lifetime is related with ambient temperature, depth of discharge, discharge rate and float
charging voltage. In real usage, deep discharge, frequent discharge, and incorrect float
charging voltage will affect the battery lifetime directly.
℃
Float Charge Voltage: 2.30V/Cell
Float Life characteristic curves are as below:
Float Lifetime vs Temperature
According to Arrhenius equation, battery design life
fluctuated with temperature, temperature increased
every 10degree, the float lifetime cut half.
K1： Equal constant at T1 temperature
K2： 1（Equal constant at T2 temperature）
Ea: activation energy
R: air constant, 8.3143J·mole · K
T1: environment temperature at during
discharge, K
T2: standard temperature 293K
-1 -1
6

9 Maintenance
8 Record
The operating record of fixed batteries is very important for battery maintenance and
protection. This information is useful for user to confirm battery life and adjust the
longevity.
Battery is allowed to operate at a temperature lower than 25℃ , however, the charging
time will be relatively long. After installing batteries and a week of float charge, it's
required to record the following information:
1）Battery terminal voltage
2）Charger voltage
3) Float charging voltage of each battery
4）Internal resistance of each battery. Within the same battery, put the meter that tests
internal resistance at the two terminals that is in farthest diagonal position.
5）Environment temperature
6) Check if all the connecting points have been fixed to the proper torque （11.3N.M）.
Use a milliohmmeter to test internal resistance of each connecting strip. Conduct
the test according to the probe potion on the instruction manual. If the data range
is 20% bigger than that during installation, fix screws again to the torque of 11.3N.M.
If the data remains high, please wipe terminals and the interface between terminals and
connecting strips.
Put mask or protective glass when approach battery, make sure not put battery next to fire/
smoking place.
It can prolong battery life and easy to judge when battery need replacement by proper
maintenance. If the maintenance way differs from this manual, users can only make
the maintenance method according to battery usage and using reliability. All
maintenance needs the professionals to execute.
1．Checking
Try to make all checking under float charging conditions. Measurements should be made
according to specification from suppliers and keep the records for future collation.
1．1 Monthly checking
Record for monthly checking：
1．1．1 All batteries float charging voltage
1．1．2 Current and voltage from charger
1．1．3 Temperature, ventilation and monitor equipments situation.
1．1．4 Eye check record for battery string:
1）Battery appearance: terminal, connector, any corrosive phenomena with battery
rack.
2）The clearance region between batteries and rack
3）Any phenomena of crack or leakage for battery
4）Any phenomena of deformation for battery and rack
1．2 Quarterly checking
Apart from checking items of above 1.1 as quarterly checking , plz also check following
issues and keep record. ( Need to collate with previous records.）
1）Resistance per block
2）Temperature of negative terminal for each battery
3）Check connect resistance at random ( at least check 10% or not less than 6
connectors), if resistance is higher than initial resistance, then need to check all
connectors' resistance and dig out reason. ( Plz check different connectors
each time)
7

1．3 Yearly checking and initial checking
Apart from checking items of above 1.1 and 1.2 as yearly checking, plz also
checking following issues and keep record ( Need to collate with previous records.）
1）Check all connector resistance;
2）Try to check AC current and voltage from rectifier.
1．4 Special checking
Batteries need inspection to check if they were get damaged in special situation
(like over-discharge, abuse charging machine or charging machine can not work
properly ect). The inspection includes all yearly checking clause and make
records.
2. Ripple Voltage of rectifier
We recommend ripple Voltage of rectifier should not be bigger than 0.5% of charging
voltage, and librating ripple time should be shorter than 8 millisecond.
3. Battery cleaning
Use water or carbonic acid water to clear battery and cover.
4. Capacity test
If batteries can work properly, no need to check capacity. Only to check capacity
when doubt battery capacity. Battery cut voltage after discharge should not be
lower than suppliers specification.
Before capacity testing, make sure battery get fully charged for more than 48 hours
under float charge, if not, make a equalization charge for 24 hours. Let batteries rest
and cool down for 8-24 hours and then conduct capacity test.
10 Common Faults & Solutions
1
2
3
4
5
6
7
No. C o m m o n F a u l t Solution
Leakage Pls contact the supplier for replacements.
Crack
Low floating V.
High temp.round pole
Abnormal Appearance
Grounding Fault
Abnormal connect & inner
resistance
Pls contact the supplier for replacements.
After 24-48hrs equalization charger, still low,
Inspect connect point, charger, ventilation and
charging current.
Pls contact the supplier for replacements.
Check leakage or ground faulty.
Check good connect or charging method.
8