Santak CASTLE Series User manual

VALVE REGULATED SEALED LEAD ACID BATTERY
Castle Series
Operation and
Maintenance
Manual

Content：
：：
：
1. Important Safety Instructions ........................................................................ 1
2. Battery storage and using circumstances ....................................................... 3
3. Using conditions ............................................................................................. 4
4. Installation of batteries .................................................................................. 5
4.1 Unpack and check ................................................................................ 5
4.2 otices before Installation ................................................................... 5
4.3 Installation and connection .................................................................. 5
5. Use of battery ................................................................................................. 7
5.1 Supplementary charge ......................................................................... 7
5.2 Discharge .............................................................................................. 7
5.3 Charge .................................................................................................. 8
6. Battery maintenance .................................................................................... 11
6.1 Cleanness ........................................................................................... 11
6.2 Inspection and maintenance .............................................................. 11
7. Exchange of Batteries ................................................................................... 16
7.1 Exchange judgments .......................................................................... 16
7.2 Exchange time .................................................................................... 16
7.3 Exchange steps ................................................................................... 16
8. Cautions ....................................................................................................... 17

1
1 Important Safety Instructions
Please read this operation manual carefully. It offers very important safety
instructions, installation and operation guide, and ensure your equipment with
best performance and prolong the service life of your equipment.
When working with any battery system, be sure you have the necessary tools and
safety equipment, including but not limited to:
insulated tools
rubber apron and gloves
face protection/face shield
safety goggles
fire extinguisher
emergency eye wash and shower, if available
acid spill cleanup kit
For the sake of your safety, please do not attempt to remove the
components of the battery. The maintenance of the battery can only be
carried out by service engineers specially trained by the principal.
Considering the potential harm of the lead component to the health and
environment, the battery can be replaced only by the service center
authorized by the manufacturer. To replace the battery or maintenance
equipment, please call the after-sales service hotline for information of the
nearest service center.
Please check the local regulations on the correct way of dealing with battery
disposal or send the battery to the authorized service center for
replacement.
Battery replacement should be operated or supervised by engineers who are
experienced and aware of the preventive measures on the potential harm of
the battery.
Avoid any possible reasons for shorting, explosions and personal injury.
Warning - Do not smoke and refrain having fire near the battery.
Warning - Do not use any organic solvent to clean the battery.
Warning - Do not have fire near the battery or it may explode.

2
Warning - Do not remove the components of the battery as it contains
electrolyte that may cause injury to the human body.
Warning - Battery may cause short circuit. Please remove any watches and
jewelry during replacement of the battery, and operate with tools with
insulated materials.

3
2 Battery storage and using circumstances
Storage
If the battery has high temperature or poor ventilation during storage
and delivery, self-discharge will be increased. Therefore, keep good
ventilation and keep away from fire, flame, water and heat supply etc.
When storing the battery, disconnect charger and load, Store in dry and
cool conditions.
After storing for any certain time, please charge the batteries before
use.
Using circumstances
o fire, flame or heat supply should be near the battery;
Avoid operating near heat supply and in direct sunlight;
Avoid operating in humid / damp locations;
Do not operate in sealed enclosed or without ventilation.

4
3 Using conditions
Temperature range:
Charging: 0 ~ +40 ℃
Discharging: -15 ~ +50 ℃ ,
Storage: -15 ~ +40 ℃ ;
Optimum ambient temperature: +20 ℃ ~ +30 ℃ .
Parallel connection: recommended within 4 groups;
Multilayer installation: temperature among layers should be controlled
within 3 ℃ ;
Heat dispersing: maintain 20mm inter-bloc distance between
batteries.
Ventilation: Ensure batteries are stored and used in
ventilated conditions.
Float charge (25 ℃ ) : limited current ≤0.30C10, voltage 2.23~2.27V/cell
Equalizing charge (25 ℃ ): limited current ≤0.30C10, voltage 2.35~2.40V/cell
Mixing batteries: Do not mix new and old batteries, batteries from
different manufacturers, if required consult Santak technical support.

5
4 Installation of batteries
4 1 Unpack and check
Delivery: Prevent any force on the terminal; do not tamper with
any seals.
Do not place upside down, Do not throw or cause any
impact to the battery;
Do not cause any metallic short circuit.
Inspection: packaging / appearance of battery for signs of damage;
Check parts list: battery quantity; accessories;
Reference: catalogue; installation drawing; other notices.
4 2 Notices before Installation
If no abnormity after check, install the batteries in the designated position;
If installing the batteries in the battery chamber, place them starting at the
bottom of chamber;
Avoid installing the batteries near any heat supply such as transformers or
heat exhaust of other equipment;
A battery may cause flammable gas during storage, avoid enclosing with any
apparatus which produce flames / sparks;
Before connecting, clean the terminals to bright metal;
Ensure that no conductive material can connect between positive and
negative terminals;
Before installation all tools are insulated.
4 3 Installation and connection
Use insulated tools only;
Connect batteries, then connect battery group with charger or load;
When multi-group batteries are parallel connected, connect in series first
and then parallel connection;
To ensure good ventilation, the batteries per row should keep around 10 -
20mm inter-bloc spacing;
Before connection, clean the battery terminals to bright metal;
Before and after connection, apply antirust compound such as petroleum gel
on the surface of battery terminal;
After batteries are installed, test the voltage of the battery group, if correct
link battery to load.

6
Use correct torque on all terminals, ensuring every connecting nut and screw
is secure; see torque settings as table 1.
Table 1 Suggested torque table
S/N Range Torque
1 M5 2.0 ～ 3.0 *m (20 ～ 30kgf*cm)
2 M6 3.9 ～ 5.4 *m (40 ～ 55kgf*cm)
3 M8 11 ～ 14.7 *m (111 ～ 150kgf*cm)

7
5 Use of battery
5 1 Supplementary charge
During the delivery and storage, the battery will lose part of the capacity due
to self discharge, so please supplement charge before use;
If storage occurs before installation / connection, supplement charge
regularly; Supplementary charge according table 2 below before use:
Table 2 The time interval of supplementary charge and storage temperature
Storage
temperature
Time interval of
supplementing charge Supplementing charge way
20
℃
or less Every 9 months a) Charging at a constant voltage of
2.23-2.27V/cell and initial current to be
less than 0.3C (A) for 2-3days b)
Charging at a constant current of
0.3C(A) and a constant voltage of
2.30-2.40V/cell for 10-16 hours c)
Charging at a constant of 0.1C(A) for
8-10 hours
20
℃
~30
℃
Every 6 months
30 ℃ ~40 ℃ Every 3 months
Note:
Current value C is rated capacity of battery. Example: rated capacity of 2V300AH
battery is 300AH, 0.1C (A) = 0.1X300 = 30A;
5 2 Discharge
Ensure the maximum allowable discharge current does not exceed the value
below ：
Discharge current I≤1C10 (A), continuous discharge;
Final discharge protective voltage as table 3 below:
Table 3 Final discharge voltage
Discharge rate Current of
discharge(A)
Final discharge
voltage (V/cell)
Testing standard of
capacity
10h 1.0I
10
1.8 ≥1.00C
10
5h 1.7I
10
1.8 ≥0.85C
10
3h 2.5I
10
1.75 ≥0.75C
10
1h 5.5I
10
1.75 ≥0.55C
10
Note:
Do not let terminal voltages drop below the above specified values.

8
Do not store after discharge, re-charge immediately.
5 3 Charge
5 3 1 Float charge
Charge parameter
Charge voltage: 2.25V/cell(25 ℃ )
The maximum charge current: 0.30C10
Temperature compensation coefficient: -3mV/cell
Total variation range of charge voltage: ±0.02V/cell
Note:
1. All cell/bloc voltages of a battery group have a little difference at the beginning
of use, half year later they become matched.
2. Effect from too high float voltage or too low float voltage as below: Too high for
a long time (overcharge): life shortened too low for a long time (not charge
enough): Cannot meet load and/or make battery voltages inconsistent. The
battery group capacity will drop accordingly and life is shortened.
5 3 2 Cycle use charge
Charge parameter
Charge voltage: 2.40 V/cell(25
℃ )
The maximum charge current: 0.30C10
Temperature compensation coefficient: -5mV/cell
Total variation range of charge voltage: ±0.02V/cell
Supplementary charge capacity is 110% ~ 130% of discharge capacity,
ambient temperature is below 5 ℃ , if do not know how many discharge
capacity, please refer to the following table to supplementary charge:
Table 4 Supplementary charge
Ambient temperature ( ℃ ) Charge voltage (V/cell) Charge time (h)
5 2.31 7
2.46 4
20 2.25 7
2.40 4
35 2.21 7
2.34 4