RITAR DG Series User manual

RITAR INTERNATIONAL GROUP LIMITED
Technical Manual
DG Series VRLA Battery
DG

Item Page
Prolegomenon
1 Application Range
2 Check
3 Storage before Installation
4 Installation Cautions
5 Battery Features
6 Working 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 properly.
★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.
your
No Sparks, Fire
or Smoking.
Vitriol:
May cause blindness
or severe burns.
Wash eyes with clean water
immediately and get medical
help ASAP.
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 DG(Deep Cycle GEL) series VRLA stationary battery (hereafter referred to
as battery).
2Check
1. After receiving the batteries, please check the packing and make sure the batteries are intact. Avoid impact
during carrying, and be careful when open the cartons.
2．Please open the cartons near the installation place and check appearance and quantity of the battery accessories.
3．It's difficult to detect leakage if there are slight damages on the battery shell. Please check carefully and make
sure there is no damage or leakage on the battery shell.
4 . If the battery falls to the ground or its shell abnormally, please report the details to our company for
confirmation and aftermath arrangement.
gets hit
3Storage before Installation
1． Storage Environment
If batteries are not installed immediately after being received, please store them 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 batteries for
over 12 months or will be affected eternally. After being stored for 6 months,
batteries should be equalize charged in voltage of 2.40 ± 0.1V/cell for 24 hours and hereafter
should be equalize 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 by half. For example, when at 35℃,
initial charging or recharging interval should be 3 months.
If a battery is not charged properly, its performance and life will be affected and cause the normal
guarantee invalid.
the battery performance
the the

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 hit 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 damp cloth; to prevent static and spark,
do not use any duster or dry cloth to clean the battery. It's prohibited to use organic
solvent such as rubber or naphtha, which will cause the battery shell cracking.
8．In normal operation, there will be no dissociative electrolyte on the shell after
battery gets fully sealed. However, if the battery shell is damaged, dissociative vitriol is
possible to leak out. In case electrolyte splashes into eyes, and onto 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.
solution
11．Battery poles, terminals and accessories contain lead or lead compounds; lead and some
other chemical substances in battery are harmful to human body.
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.
Working Principle
3
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 state, part of PbO at the
2
positive turns into PbSO , and part of Pb at the negative also turns into PbSO4. In this electro-
4
chemical reaction, both positive and negative electrodes generate PbSO . In the charging state,
4
the lead sulfate(PbSO ) at the positive and negative turns into PbO and Pb, respectively. When in
4 2
discharging, the concentration and density of H SO decreases gradually; while in charging, it
2 4
increases. Battery charging and discharging are realized by electrochemical reactions.
2. Oxygen Combination
The positive plate generates oxygen gas in the final stage of charging. Under the condition of
excessive additives at the negative, oxygen spreads to the negative plates through PE compound
separator and reacts with spongy lead and forms lead oxide and then turns into lead sulfate and
water. Keep the negative plates in depolarization or under charge state so that the battery cannot
reach the over potential of oxygen gassing. Thus the battery avoids oxygen gassing and water
loss and is made a maintenance free sealed storage battery.

0.0 4
0.0 8
0.1 2
0.1 6
0.2 0
0.2 4
0.2 8
7 Battery Charge, Discharge & Life
1. Charge Characteristics
Charge condition is one of the most 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
℃
Charge Characteristic Curve of Float Use
Charge Volume (%)
Charge Current (A)
Charge Voltage (V)
Charge Time (Hr)
Charge Voltage
Charge Volum e
Discharge
Charg e with
& Limit ed Curren t :
Charg e Voltage: 2 .30V/Cell
Charg e Current : 0.2
Const ant Voltag e
C A
20
Tempera ture: 25℃/77℉
4
In the process of using batteries, due to the individual differences and temperature differences of batteries,
long term floating charge operation will result in unbalanced battery terminal voltage (backward battery). In
order to avoid the deterioration of this imbalance trend, it is necessary to increase the charging voltage of
the battery bank and charge the battery bank to equalize the whole battery bank. Proper equalizing voltage
and equalizing frequency are the basis of long life and reliability of battery. Equalizing charge is not
recommended in the normal use of VRLA batteries, because equalizing charge will increase water loss and
grid corrosion, which will cause early failure.
Equalizing charge requirements for RITAR battery are as follows:
※ The equalizing charging voltage is related to the ambient temperature. The equalizing charging voltage
of single cell is 2.35v-2.45v/cell at 25 ℃. If the temperature changes, adjust the equalizing voltage in
time, and the equalizing voltage temperature compensation coefficient is - 4MV /℃.
※Equalize charge batteries 1 time after three months of fully float charge operation according to the
specified voltage. Discharge batteries 100% before equalizing charge.
※Equalizing charge setting: equalizing charge voltage is 2.35~2.45V/cell @25℃ and equalizing charge
time is 12 or 24 hours (when the charge current at the end stable about 2~3 hours ,stop equalize and
switch to float ).
※Under special circumstances, if the battery is cycle used continuously for more than 20 times, it needs
to be equalize charged once.
※In the battery bank, if there is a backward battery, and the single voltage is lower than 2.18V in floating
charge state; or after the battery is replaced in the battery bank, it needs equalizing charge.
4. Equalizing Charge Parameters

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 Charge
7. Discharge Characteristic
Discharge characteristic curves are as right:
Discharge Capacity vs Temperature
Remaining Capacity (%)
Capacity Reservation Curves
No need of suppl ementary
charging. Us ed in float
charge.
Supplementary Charging
is required.
Supplementary 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 12 30 1 2 5 10 2 0 24
Mi n H r
3C 1 C
0.6 2C 0.35C
0.16C 0.093C
0.05C
5
Due to self-discharge, the battery capacity reduces
slowly in long time storage. A supplementary charge is
required prior to installation. For the relationship of
capacity, temperature and storage time, please see
the right curve figure. Apply supplementary charge
with constant voltage but limited current: charging
curr ent i s 0 .05C -0.2 C ; c h argi ng volt age i s
2 0 2 0
2.35±0.05V/Cell; charge time is 24~36 hours.
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
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.
CA
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.
Charge Characteristic Curve of Cycle Use
Charge Volume (%)
Charge Current (A)
Charge Voltage (V)
Charge Voltage
Charge Volum e
Discharge
Charg e with
& Limit ed Curren t :
Charg e Voltage: 2 .40V/Cell
Charg e Current : 0.2
Const ant Voltag e
C A
20
Tempera ture: 25℃/77℉
Charge Time (Hr)
20
20
According to the difference of discharge rate,
the cutoff voltage is also different. Larger
discharge current sets lower cutoff voltage;
reversely, smaller discharge current sets higher
cutoff voltage. Normally the battery cutoff
voltage of single cell discharge is set at 1.8 0 –
1.60V. The discharge capacity decreases with
the increase of discharge current; the discharge
capacity increases with the decrease of
discharge current.
Battery discharge capacity is related with temperature. Lower temperature, lower discharge
capacity; higher temperature, higher discharge capacity. But over high temperature will seriously
damage the battery lifetime. The best working temperature for battery is 20- 25℃. The discharge
capacity at a certain temperature Ct vs the discharge capacity at 25℃ C25 have below relationship:

Temperature vs Capacity Curve
120
110
100
80
60
40
0-40 -30 -20 -1 0 -0 10 20 30 40 50 Temperature
（℃）
Effective Capacity (%)
Float Life Characteristic Curves
20 30 4 0 50 C
68 8 6 10 4 12 2 F Temperature
20
16
10
14
8
6
4
5
3
2
1. 4
1
Life(Year)
Float Charge
Voltage(V)
2. 3 0 15. 0 1 0.6 7 .5 3. 7 1. 9
20 C 25C 30 C 40 C 5 0C
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 Discharge capacity at 25 (AH)
Ct Discharge capacity at t℃ (AH)
t Environment temperature during discharge (℃)
K Temperature compensation coefficient
℃
Temperature vs Capacity Curve 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 to 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
fluctuates with temperature, temperature increases
every 10 degree, the float lifetime is cut by 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 during
discharge, K
T2: standard temperature 293K
-1 -1
6

9 Maintenance
8 Record
The operating record of stationary 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 on a mask or a pair of protective glasses when approach batteries, make sure not put batteries next
to fire/ smoking place.
Proper maintenance can prolong battery life and help it meet the design requirements. A good battery
maintenance program can help to judge when battery need to be replaced. If the maintenance way
differs from this manual, users can make the maintenance program according to battery usage and
using reliability. All maintenance needs to be executed by professionals.
1．Inspection
Try to make all inspection under float charging conditions. Inspection should be conducted according
to instruction manual from the supplier and record all test data for future collation.
1．1 Monthly inspection
General inspection items and record of every month are as follows：
1．1．1 Float charging voltage of all batteries.
1．1．2 Output current and voltage of charger.
1．1．3 Ambient temperature, ventilation and monitor equipments.
1．1．4 Visual inspection of battery bank appearance:
1）Inspect battery appearance: Check whether there is corrosive phenomenon on terminals,
connectors, battery racks.
2）Clean batteries, racks and battery region.
3）Inspect whether there is crack or leakage on battery.
4）Inspect whether there is deformation of battery and rack.
1．2 Quarterly inspection
Quarterly inspection includes the items in 1.1 and the followings; please record all the inspection data.
( Need to collate with previous records.）
1） Internal resistance of each battery cell;
2） Temperature on negative terminals of each battery cell;
3） Inspect connect resistance at random ( at least check 10% or 6 connectors), if resistance is
significantly higher than the initial value, then need to check all connectors' resistance and dig out
reason. (Notice: Please inspect different connectors every quarter.)
7

1.3 Yearly inspection and initial inspection
For Yearly inspection and initial inspection, conduct all the 1.1, 1.2 and following
checking items and record them.
1）Check and record internal resistance of all connectors;
2）Try to check AC current and voltage from rectifier.
1.4 Special inspection
Batteries need inspection to check if they get damaged in special situations (such as
over-discharge, abuse use due to charging machine failure, etc). The inspection
includes all yearly checking items and needs to 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 cloth soaked in water or carbonic acid water to clear battery and cover.
4. Capacity test
If batteries work properly, no need to check capacity. Check capacity only when
battery capacity is in doubt. When battery is in discharge, the cut-off voltage should
not be lower than the requirement in the technical manual.
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
8
1
2
3
4
5
6
7
No. Common Faults Solutions
Acid leakage Please contact the supplier for solutions.
Crack
Low floating voltage of single cell
High temperature on battery pole and
cell
Abnormal Appearance
Grounding Fault
Abnormal connect & inner
resistance
Please contact the supplier for solutions.
After 24-48hrs equalization charger, still low, p
.
lease contact the supplier for
solutions
Check whether the connection is good, inspect charger, ventilation and charging
current.
Clean dust, and check leakage or ground faulty. The battery bank shall be
insulated from the ground.
Please contact the supplier for solutions.
Check whether the connection is good, inspect charger, ventilation and
charging current.