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.

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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)

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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

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Note:
1. Charge time is the time when terminal voltage reaches value as the above
table shows during charging at a constant 0.30C (A) or less.
2. If the charge time is over the time as above table, it will cause over charge,
which will shorten the life of the batteries; if the charge time is less than the
time as above table, the batteries cannot meet the normal capacity.
5 3 3 Equalization charge
Charging parameter
Charging voltage : 2.35V/cell (25 ℃ )
Maximal charging current : 0.30C10
Temperature equalization parameter: -3mV/cell
Variation scope of charging voltage: ±0.02V/cell
Note:
Do not carry this operation under standard float charging. Adopt equalization
charging under below situations:
Discharging capacity is above 20% of rated capacity.
Lay aside the battery without using it for more than 3 months.
Float voltage of battery unit is less than 2.18V/cell
Continuously float charging battery for 3 ~ 6 months or low voltage batteries
appears in battery group.
More than 1 year fully under float operation
Supplementary charge the battery after installation and before using.
Equalizing charge the battery after the capacity test.
5 3 4 Notes during charging
Charge current at the end of charge is over 0.05 C10A, which may result in
permanent damage on battery appearance and battery life; pay more
attention to charging voltage.
The used charger should have digressive automatic constant voltage device,
please contact us if use other kind of charger.
If the ambient temperature is not 25
℃ , temperature compensation should
be applied on the voltage, using the formula is U=U25
℃ - K×(T -25)
T—ambient temperature; K—temperature compensation coefficient
Judgment on charge end point, usually, if the battery charge can meet any

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one of the below listed condition, it can be regarded as the charge end point.
a) Charged value is not less than 1.2 times of the released value.
b) The current is less than 0.005C10A (C10 = rated capacity of the battery)
during the final period of charging.
c) The current is steady for 5 hours during the final period of charging.

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6 Battery maintenance
6 1 Cleanness
Keep the battery surface and its working circumstance clean and dry.
Keep battery clean and avoid static condition.
Clean battery with damp cloth avoiding contact with terminals, no organic
solvent such as gasoline, alcohol etc. or clothes with such substance should
be used to clean battery.
6 2 Inspection and maintenance
To better understand the operation of battery and equipment and also to prevent
battery damage during maintenance inspection, please periodically inspect the
battery and record it.
6 2 1 Inspection items per month:
Items Contents Standards Maintenance
Total float
charging
voltage of
battery group
Measure output end
voltage of positive
and negative end of
battery group with
voltage meter.
1. tested data comply
with the data
displayed
on the meter and
meet the voltage
standard under
the temperature
conditions
2. The error of float
charge voltage after
temperature
compensation Is
≤±50mV
1. If data attained by
testing is varies from the
standard, the tested data
should prevail.
2. For those adjusted by
monitor module and still
can’t reach the allowed
error range after module
adjustment, repair is to
be applied or send them
back to factory.
Battery
appearance
Inspect battery case
and cover for bulge,
leakage or damage.
ormal Find out the reasons if
abnormal appearance
exist, please change
battery if it effects the
normal use of battery
group
Inspect for dust or
stains
Clean Clean the dust and stain
with damp cloth.
Inspect the harness
and terminal for rust
or corrosion.
o rust Clean the rust, change
the harness and paste
with antirust
coating/paste.

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Temperature
of the
battery
Test the
temperature of the
terminal and battery
surface by infrared
thermometer
Under 35 ℃ Determine reason for
temperature being
above standard value
and proceed on relevant
course of action.
Connection
Parts
Check the tightness
of terminal
bolt/screw with
torque spanner
Fastness please refer
to the table of
torque ）
Tighten the loosen
bolt/screw in time
Check the
connection cable and
terminals for dirt and
corrosion
Without appearance
of corrosion or dirt
Take out the connection
cable and clear it in
water if it is light
corrosion, for serious
corrosion please replace
the cable and clear the
connection point with a
steel brush before
attaching new
connectors
Switch DC
power supply
Cut off AC power
supply and change to
UPS or DC power
supply
AC power supply
switch to UPS or DC
power supply
smoothly
Correct the potential
difference
6 2 2 Inspection items per quarter
Apart from the maintenance per month, additional articles added as below:
Items Contents Standards Maintenance
Float voltage
of each battery
Measure the end
voltage of each
battery in battery
group.
Float voltage value
after temperature
equalization ±50mV
If float voltage is
over standard value,
please apply
Equalization charge
the battery group
after discharging
them and then float
charge them for 1
～
2 month, please
contact us if still
have any deviation
from standard.

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Repair batteries
which with laggard
single cell
1. Equalization
charge of the
battery group:
charge the battery
at upper limit
voltage and last
more than 10H, 3
times of discharge
cycle is necessary
when case is
serious.
The difference of
float charge voltage
between
single cell in a group
of battery should
meet the
below standard:
12Vseries 480mv
Single cell should be
replaced if it fails in
repair.
2. On-line repair of
single cell:
connect the cell the
activation meter or
charger with the
laggard battery and
charge the single
cell.
Activation
charge and
discharge
Charge and
discharge the
battery by one
cycle, then charge
the battery by the
lower limit of the
equalization voltage
About 30% of the
rated capacity is
released.
Produced this text
on the batteries
which float charge
more than 6moths
but without
discharge.
6 2 3 Inspection item per year
Apart from the maintenance per quarter, additional articles added as below:
Items Contents Standards Maintenance
Checking
discharge test
Cut off AC power
supply, discharge
battery with load,
and discharging
30%
～ 40%
rated capacity.
Battery voltage
should be over
1.90V/cell after
discharging.
If battery voltage is
lower than
standard value,
please equalization
charge the battery
group after
discharging and
then float charging

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it for 1 ～ 2 month,
please contact us if
still have any
departure.
Capacity test Adopt the
on-system
capacity test
instrument or
fake load
discharge battery
and discharge
60~80%of the
rated capacity
More than 80% of
the capacity is
reserved.
Take down the
parameters during
the discharging
test, if any laggard
battery is found,
please proceed to
relevant operation.
Requirements:
1) Principle “find out the hidden trouble and insure the safety” Should be
complied when make test on the battery.
2) Daily maintenance and performance analysis should be carried out strictly
according the processing plan.
3) Battery parameter setting operation should be strictly complied with the
maintenance rules and related requirement.
4) Always wear insulated gloves when handling the batteries to avoid electric
shock. Make sure the metal instrument is insulated.
5) Use instrument and meters which meet the test requirement.
6) Physical articles:
a) Check whether the post and connection is clean or not, whether there is
any appearance of oxidation or corrosion. In case it is serious, please
clear it and reduce the resistance.
b) Check for any loose connection, if any, please tighten them up.
c) Check if there is any appearance of acid climbing, leakage of liquid, and
whether there is liquid overflow around the safety valve.
d) Check if there is any damage, leakage and distortion on the battery case
and the post; it should be without any damage and distortion.
e) Check there is any abnormal temperature increase on the battery and its
connection.

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7) Check and adjust the set of related parameters.
a) Check the float voltage, equalization voltage, float charging current is
normal or not on the base of technical parameters and site environment.
Please handle it in time.
b) Check the limited charge current set is correct, please adjust
immediately.
c) Check the alarm voltage (below voltage and over voltage alarm) of the
battery set is correct, if not, please adjust promptly.
d) If there is off-load set, please check the off-load voltage is correct, if not,
please adjust promptly.

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7 Exchange of Batteries
7 1 Exchange judgments
The batteries are discharged 80% (refer the corresponding discharge rates, such
as C10, C1 etc.) of rated capacity, at the same time, the voltage is below 1.8V/cell
(the discharge rate for 1 hour is 1.75V/cell). It should be exchanged.
7 2 Exchange time
The VRLA GEL battery has the certain service life; please replace the old battery
with the new one before the end of service life so that the application can run
safely and normally.
7 3 Exchange steps
Step 1: Disconnect the battery’s inter-cell connectors and inter-tier
connectors.
Step 2: The batteries remove should be operated from the top to down, such
as disassembly one of the top lateral frame to remove the top layer batteries.
And then the second top layer. Until all batteries are removed from the rack.
Step 3: For installing the new batteries and, please refer to the section 6.5;
Note:
Sometimes, the cables need to be reused according to the requirement. Don’t
hurt the cables during disconnect.

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8 Cautions
Keep batteries out of reach of children.
Do not use batteries for application other than those specified in its
specification.
Do not attempt to dis-assemble revised, damaged, impacted, disposed
batteries, otherwise the battery would leak, get hot, or explode.
Do not dispose of the batteries in water, fire, and do not heat the batteries.
Do not cause any short circuit
If the voltage of battery pack is above 45V, please be sure to wear insulated
gloves when working; otherwise, there is a risk of severe electrical shock.
Do not bring face close to the top of batteries, please keep a sensible
distance when you are measuring and repairing, you must wear safety
goggles.
There is sulphuric acid in the battery, do not allow contact of sulphuric acid
with skin, cloths, especially eyes. If eyes come in contact with sulphuric acid,
please wash with a lot of clean water, and consult a physician immediately.
Longer service life will be attained when the battery is operated within an
ambient temperature range of 20~30
℃.

www.santak.com
SANTAK ELECTRONICS (SHENZHEN) CO , LTD
Address: No.8 Baoshi Road, Baoan District, Shenzhen, 518101
Tel: [phone]
Fax: [phone] (27572480)
E-mail: Santak_in[email protected]
Website: www.santak.com