Operation and

VALVE REGULATED SEALED LEAD ACID BATTERY

Castle Series
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 Notices 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. 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.

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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

No 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.

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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.

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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.
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 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 N*m (20 30kgf*cm)
2 M6 ～ ～
3.9 5.4 N*m (40 55kgf*cm)
3 M8 11～14.7 N*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 Time interval of
Supplementing charge way
temperature supplementing charge
20℃ or less Every 9 months a) Charging at a constant voltage of
20℃ ~30℃ Every 6 months 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

30 ℃ ~40℃ Every 3 months

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
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
Current of Final discharge Testing standard of
Discharge rate
discharge(A) voltage (V/cell) capacity
10h 1.0I10 1.8 ≥1.00C10
5h 1.7I10 1.8 ≥0.85C10
3h 2.5I10 1.75 ≥0.75C10
1h 5.5I10 1.75 ≥0.55C10
Note:
Do not let terminal voltages drop below the above specified values.
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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 Measure output end 1. tested data comply 1. If data attained by
charging voltage of positive with the data testing is varies from the
voltage of and negative end of displayed standard, the tested data
battery group battery group with on the meter and should prevail.
voltage meter. meet the voltage 2. For those adjusted by
standard under monitor module and still
the temperature can’t reach the allowed
conditions error range after module
2. The error of float adjustment, repair is to
charge voltage after be applied or send them
temperature back to factory.
compensation Is
≤±50mV
Battery Inspect battery case Normal Find out the reasons if
appearance and cover for bulge, abnormal appearance
leakage or damage. exist, please change
battery if it effects the
normal use of battery
group
Inspect for dust or Clean Clean the dust and stain
stains with damp cloth.
Inspect the harness No rust Clean the rust, change
and terminal for rust the harness and paste
or corrosion. with antirust
coating/paste.
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Temperature Test the Under 35 ℃ Determine reason for
of the temperature of the temperature being
battery terminal and battery above standard value
surface by infrared and proceed on relevant
thermometer course of action.
Connection Check the tightness Fastness please refer Tighten the loosen
Parts of terminal to the table of bolt/screw in time
bolt/screw with torque ）
torque spanner
Check the Without appearance Take out the connection
connection cable and of corrosion or dirt cable and clear it in
terminals for dirt and water if it is light
corrosion corrosion, for serious
corrosion please replace
the cable and clear the
connection point with a
steel brush before
attaching new
connectors
Switch DC Cut off AC power AC power supply Correct the potential
power supply supply and change to switch to UPS or DC difference
UPS or DC power power supply
supply smoothly

6.2.2 Inspection items per quarter

Apart from the maintenance per month, additional articles added as below:
Items Contents Standards Maintenance
Float voltage Measure the end Float voltage value If float voltage is
of each battery voltage of each after temperature over standard value,
battery in battery equalization ±50mV please apply
group. 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 1. Equalization The difference of Single cell should be
which with laggard charge of the float charge voltage replaced if it fails in
single cell battery group: between repair.
charge the battery single cell in a group
at upper limit of battery should
voltage and last meet the
more than 10H, 3 below standard:
times of discharge 12Vseries 480mv
cycle is necessary
when case is
serious.
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 About 30% of the Produced this text
charge and discharge the rated capacity is on the batteries
discharge battery by one released. which float charge
cycle, then charge more than 6moths
the battery by the but without
lower limit of the discharge.
equalization voltage

6.2.3 Inspection item per year

Apart from the maintenance per quarter, additional articles added as below:
Items Contents Standards Maintenance
Checking Cut off AC power Battery voltage If battery voltage is
discharge test supply, discharge should be over lower than
battery with load, 1.90V/cell after standard value,
and discharging discharging. please equalization
～
30% 40% charge the battery
rated capacity. 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 More than 80% of Take down the
on-system the capacity is parameters during
capacity test reserved. the discharging
instrument or test, if any laggard
fake load battery is found,
discharge battery please proceed to
and discharge relevant operation.
60~80%of the
rated capacity
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 ℃.

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www.santak.com

SANTAK ELECTRONICS (SHENZHEN) CO., LTD.

Address: No.8 Baoshi Road, Baoan District, Shenzhen, 518101
Tel: 0086 755 27572666
Fax: 0086 755 27572730 (27572480)

E-mail: Santak_int@eaton.com
Website: www.santak.com