Installation Procedure of Battery Bank

GFM SeriesValve-Regulated Lead-Acid Battery

User’s Manual (C)

Version 1.0

ZTE CORPORATION ZTE Plaza, Keji Road South, Hi-Tech Industrial Park, Nanshan District, Shenzhen, P. R. China 518057 Tel: (86) 755 26771900 800-9830-9830 Fax: (86) 755 26772236 URL: http://support.zte.com.cn E-mail: [email protected]

LEGAL INFORMATION Copyright © 2005 ZTE CORPORATION. The contents of this document are protected by copyright laws and international treaties. Any reproduction or distribution of this document or any portion of this document, in any form by any means, without the prior written consent of ZTE CORPORATION is prohibited. Additionally, the contents of this document are protected by contractual confidentiality obligations. All company, brand and product names are trade or service marks, or registered trade or service marks, of ZTE CORPORATION or of their respective owners. This document is provided “as is”, and all express, implied, or statutory warranties, representations or conditions are disclaimed, including without limitation any implied warranty of merchantability, fitness for a particular purpose, title or non-infringement. ZTE CORPORATION and its licensors shall not be liable for damages resulting from the use of or reliance on the information contained herein. ZTE CORPORATION or its licensors may have current or pending intellectual property rights or applications covering the subject matter of this document. Except as expressly provided in any written license between ZTE CORPORATION and its licensee, the user of this document shall not acquire any license to the subject matter herein. The contents of this document and all policies of ZTE CORPORATION, including without limitation policies related to support or training are subject to change without notice.

Revision History

Date Revision No. Serial No. Description

2005/09/30 R1.0 sjzl20051834 First version

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Document Name GFM Series Valve-Regulated Lead-Acid Battery (V1.0) User’s Manual (C)

Product Version V1.0 Document

Revision Number R1.0

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Contents

About this User’s Manual ..........................................................................ix Purpose of this User’s Manual ................................................................................. ix Typographical Conventions......................................................................................x Mouse Operation Conventions..................................................................................x Safety Signs.......................................................................................................... xi How to Get in Touch ..............................................................................................xii

Customer Support..................................................................................................................xii Documentation Support..........................................................................................................xii

Chapter 1...................................................................................13

Safety Instructions.................................................................................. 13 Overview .............................................................................................................13 Instructions..........................................................................................................13

Chapter 2...................................................................................15

Features and Specifications.................................................................... 15 Model Definition....................................................................................................15 Features ..............................................................................................................15 Specifications .......................................................................................................17

Chapter 3...................................................................................19

Structure and Principle ........................................................................... 19 Appearance..........................................................................................................19 Operating Principle................................................................................................20

Chapter 4...................................................................................21

Installation .............................................................................................. 21 Check Installation Site...........................................................................................21 Precautions ..........................................................................................................21

Installation Mode ..................................................................................................22 Installation Procedure ...........................................................................................25

Installation with Double-/Single-Layer Vertical Rack................................................................25 Installation with Three-Layer Vertical Rack/Cabinet.................................................................26

Installation Diagram..............................................................................................26 Check after Installation .........................................................................................37

Chapter 5...................................................................................39

Operation and Maintenance.................................................................... 39 Operation.............................................................................................................39

Operation Precautions............................................................................................................39 Charge..................................................................................................................................39 Capacity Detection ................................................................................................................41 Discharge..............................................................................................................................42 Parameter of Switch Power Supply.........................................................................................42 Requirements for Application with Power Cut..........................................................................44 Battery Replacement.............................................................................................................44

Routine Maintenance.............................................................................................45 Troubleshooting....................................................................................................46

Appendix A................................................................................47

Selection, Transportation and Storage................................................... 47

Type Selection......................................................................................................47 Transportation......................................................................................................47 Storage ...............................................................................................................48

Appendix B................................................................................49

Technical Characteristics ........................................................................ 49

Discharge Characteristic........................................................................................49 Discharge Characteristic Curve...............................................................................................49 Discharge Current .................................................................................................................50 Relation between Discharge Capacity and Temperature ..........................................................50

Charge Characteristic............................................................................................51 Lifetime Characteristic...........................................................................................51

Discharge Depth Effect on Lifetime.........................................................................................51 Working Temperature Effect on Lifetime.................................................................................52

Figures..........................................................................................53

Tables ...........................................................................................55


Confidential and Proprietary Information of ZTE CORPORATION ix

About this User’s Manual

Purpose of this User’s Manual This manual provides the basic information you need for installing, operating and maintaining the ZTE’s GFM Series Valve-Regulated Lead-Acid battery (GFM battery for short). Please read this manual carefully in advance.

This manual includes five chapters and two appendixes:

“Chapter 1 Safety Instructions” provides the safety instructions for installation, operation and maintenance.

“Chapter 2 Features and Specifications” introduces the model definition, features and specifications.

“Chapter 3 Structure and Principle” describes the structure and operating principle.

“Chapter 4 Installation” provides the installation mode, the installation procedure and the installation diagrams of some types.

“Chapter 5 Operation and Maintenance” describes operation, maintenance and troubleshooting.

“Appendix A Selection, Transportation and Storage” describes type selection, precautions for transportation and storage.

“Appendix B Technical Characteristics” describes discharge characteristic, charge characteristic and lifetime characteristic.

GFM Series Valve-Regulated Lead-Acid Battery (V1.0) User’s Manual (C)

x Confidential and Proprietary Information of ZTE CORPORATION

Typographical Conventions ZTE documents employ with the following typographical conventions.

T AB L E 1 TY P O G R AP H I C AL C O N V E N T I O N S

Mouse Operation Conventions T AB L E 2 M O U S E OP E R AT I O N C O N V E N T I O N S

Typeface Meaning

Italics References to other guides and documents.

“Quotes” Links on screens.

Bold Menus, menu options, function names, input fields, radio button names, check boxes, drop-down lists, dialog box names, window names.

CAPS Keys on the keyboard and buttons on screens and company name.

Constant width Text that you type, program code, files and directory names, and function names.

[ ] Optional parameters

{ } Mandatory parameters

| Select one of the parameters that are delimited by it

Note: Provides additional information about a certain topic.

Checkpoint: Indicates that a particular step needs to be checked before proceeding further.

Tip: Indicates a suggestion or hint to make things easier or more productive for the reader.

Typeface Meaning

Click Refers to clicking the primary mouse button (usually the left mouse button) once.

Double-click Refers to quickly clicking the primary mouse button (usually the left mouse button) twice.

Right-click Refers to clicking the secondary mouse button (usually the right mouse button) once.

Drag Refers to pressing and holding a mouse button and moving the mouse.

About this User’s Manual

Confidential and Proprietary Information of ZTE CORPORATION xi

Safety Signs T AB L E 3 S AF E T Y S I G N S

Safety Signs Meaning

Danger: Indicates an imminently hazardous situation, which if not avoided, will result in death or serious injury. This signal word should be limited to only extreme situations.

Warning: Indicates a potentially hazardous situation, which if not avoided, could result in death or serious injury.

Caution: Indicates a potentially hazardous situation, which if not avoided, could result in minor or moderate injury. It may also be used to alert against unsafe practices.

Erosion: Beware of erosion.

Electric shock: There is a risk of electric shock.

Electrostatic: The device may be sensitive to static electricity.

Microwave: Beware of strong electromagnetic field.

Laser: Beware of strong laser beam.

No flammables: No flammables can be stored.

No touching: Do not touch.

No smoking: Smoking is forbidden.


xii Confidential and Proprietary Information of ZTE CORPORATION

How to Get in Touch The following sections provide information on how to obtain support for the documentation and the software.

Customer Support If you have problems, questions, comments, or suggestions regarding your product, contact us by e-mail at [email protected]. You can also call our customer support center at (86) 755 26771900 and (86) 800-9830-9830.

Documentation Support ZTE welcomes your comments and suggestions on the quality and usefulness of this document. For further questions, comments, or suggestions on the documentation, you can contact us by e-mail at [email protected]; or you can fax your comments and suggestions to (86) 755 26772236. You can also explore our website at http://support.zte.com.cn, which contains various interesting subjects like documentation, knowledge base, forum and service request.

Confidential and Proprietary Information of ZTE CORPORATION 13

C h a p t e r 1

Safety Instructions

This chapter describes the safety instructions for battery installation, operation and maintenance.

Overview

Danger: Before any operation of the equipment, please read carefully all the safety instructions in this manual to avoid personal injury or equipment damage.

Observe the local safety codes and related operation procedures during the installation, operation and maintenance of the equipment to avoid personal injury or equipment damage. The safety precautions mentioned in this manual only serve as a supplement to the local safety codes.

ZTE bears no liability to the consequences incurred by violation of the general safety operation requirements, or violation of the safety standards for designing, manufacturing and using the equipment.

Instructions Observe the following safety instructions during installation, operation and maintenance of the equipment:

The battery pack has high voltage, so direct contact or indirect contact through wet objects with any conducting cable may result in vital injury. The battery pack is energy-storing equipment, so never short-circuit the battery pack during operation and maintenance in any way.

Do not wear any watch, hand chain, bracelet, ring and other conductive objects during operation.

Only qualified and professional personnel are allowed to install, operate and maintain the equipment.


14 Confidential and Proprietary Information of ZTE CORPORATION

Requirement for tools

Do use special tools, instead of common or your own tools during electrical connections. In addition, keep the tools in good insulation condition (e.g. wrap insulating tape around the bare metal parts) before using them to avoid short circuit and personal injury caused by tools contact with any live objects.

Requirement for battery model

Use batteries of the same model. Using batteries of different model will damage the equipment.

Fire hazard

During battery installation, make sure to fix the connecting terminals of the conducting wire tight, and keep the output terminals of the batteries clean. Otherwise, it may lead to a high temperature of battery terminals and even to spark/fire.

Only CCl4 (carbon tetrachloride) fire extinguisher can be used to put out a fire involving storage battery; instead, CO2 (carbon dioxide) fire extinguisher cannot.

Operation provisions

Before battery operations, read the safety precautions/instructions, and the operation instructions, especially the battery interconnection instructions.

Substandard operations will cause danger. Prevent battery short circuit and prevent battery electrolyte from flowing out. Overflowed electrolyte is a latent danger and it will erode the metal object and circuit board, thus damaging the equipment and causing short circuit of the circuit board.


C h a p t e r 2

Features and Specifications

In this chapter, you will learn about: Model definition of GFM series battery

Features of GFM series battery

Specifications of GFM series battery

Model Definition GFM-200 taken as an example, the model definition of GFM series battery is shown in Figure 1.

F I G U R E 1 M O D E L D E F I N I T I O N

Features The features of the GMF battery is described as follows,

Long lifetime

GFM series battery has a long service lifetime and has a high volumetric energy density (Wh/L) and a high gravimetric energy density (Wh/kg), because rectangle structure, advanced formation technology of tetrabasic lead sulfate and alloy material are used to the battery plates.

Easy to maintenance

If battery is over-charged, the gas produced by electrolysis will be completely absorbed by negative plate, and, through reaction, it will



reduce the electrolyzed electrolyte to water. Therefore, there’s no loss of water.

Low internal resistance

The terminals are made of copper cores with large diameter, so the terminals have large current-carrying capacity and small resistance.

Safety

The safety valve can automatically regulated the pressure inside battery; and the special filter prevents the chance of battery explosion.

The special seal structure and advanced weld technology are sued to the GFM series battery, and they enable the battery well sealed.

Convenient installation

Battery can be installed into a vertical rack, and also can be placed on the ground.

Charge/Discharge characteristics

Batteries equipped with absorbing super-fine fiberglass separators have low inner resistance and good high-rate discharge performance.

Highly purified electrolyte and special additive improve active material utilization, deep discharge performance and charge acceptance ability.

Special additives added to positive and negative paste as well as the optimum proportion of organic additives to inorganic additives improve the active material utilization and charge acceptance ability

Advance quality

Cover and container made of ABS and advanced heat-sealing technology improve battery intensity, safety and stability.

Specially designed flame-retardant ABS valve with column core and double filters can precisely control the air pressure to open/close the valve, and the valve is also acid-proof and explosion-proof.

Assembling plates with higher compression and U type separator prevent the influence of plate stress on separator elasticity, improve the contact of separators with plate, and make acid absorbed more even and plates cleaning.

Plastic socket between positive plate and negative plate can effectively avoid short circuit as well as the deformation of plates when the battery is placed horizontally.

Chapter 2 - Features and Specifications


Specifications The specifications of GFM series batteries are listed in Table 4.

T AB L E 4 TE C H N I C AL S P E C I F I C AT I O N S

Dimension

Model Rated Voltage (V)

Rated Capacity (Ah)

Number of Terminal Pair

L (mm)

W (mm)

h (mm)

H (mm)

Weight(kg)

GFM-200 2 200 1 101 184 347 365 14.1

GFM-300 2 300 1 132 184 347 365 18.5

GFM-400 2 400 1 163 184 347 365 23.3

GFM-500 2 500 1 194 184 347 365 28

GFM-600 2 600 2 225 184 347 365 37

GFM-800 2 800 2 303 184 347 365 50

GFM-1000 2 1000 2 373 184 347 365 61

GFM-1600 2 1600 4 403 354 345 378 116

GFM-2000 2 2000 8 492 352 340 378 135

GFM-3000 2 3000 8 712 352 340 382 200





C h a p t e r 3

Structure and Principle

In this chapter, you will learn about: Structure of GFM series battery

Operating principle of GFM series battery

Appearance Single cell structure is used to the GFM battery. The rated voltage of one cell is 2 V.

GFM battery consists of separator, electrolyte, shell and accessories.

The appearance is shown in Figure 2.

F I G U R E 2 AP P E AR AN C E O F GFM B AT T E R Y

GFM1600 GFM2000-GFM3000GFM200-GFM500 GFM600-GFM1000



Operating Principle Chemical reaction of charging/discharging

The chemical reaction of charging/discharging is shown in Figure 3.

F I G U R E 3 C H E M I C AL R E AC T I O N O F C H AR G I N G /D I S C H AR G I N G

Discharge: PbO2 on positive plate and spongy lead (Pb) on negative plate react with H2SO4 to produce PbSO4, and the concentration of H2SO4 in electrolyte is reduced.

Charge: The oxidation-reduction reaction of PbSO4 produces PbO2 and spongy lead (Pb), and the concentration of H2SO4 in electrolyte is increased.

Chemical reaction of the final charging stage

During the end period of charging, when the voltage of battery goes up to a certain value, the decomposing of water will produce oxygen on the positive plate. The reaction is:

H2O 2H→ ++1/2O2+2e-

Oxygen goes through gas passage to the negative plate and combined with spongy lead (Pb) to produce PbO.

2Pb+O2 2PbO→

PbO is alkalescence oxide and will combine with H2SO4 in electrolyte to produce PbSO4.

PbO+H2SO4 PbSO→ 4+H2O

PbSO4 will transform to spongy lead (Pb) by charging:

PbSO4+2H++2e- Pb+H→ 2SO4

The reaction on the negative plate is:

O2+4H++4e-→2H2O

During charging, the water wasted on positive plate will be compensated by the water produced on negative plate, so there’s no need to pour water, which makes battery easy to maintain.


C h a p t e r 4

Installation

This chapter describes installation instructions, including installation precautions, installation mode, installation procedure, and installation diagrams.

Check Installation Site The installation site should meet the following requirements:

Environment temperature: 24°C ~ 25°C.

The installation site should be dry, clean and ventilative, free of excessive radiation, infrared ray, organic solvent, corrosive gas and exposure to sunlight.

Precautions The precautions during installation is describes as follows:

1. Ventilation hole of heater or air conditioner and calorific part of switch power supply should not be towards the GFM battery. The temperature difference of various parts of the battery should be kept no more than 3°C. It is recommended to use an infrared thermal detector to detect the temperature of battery parts.

2. The battery can be installed into shelf or cabinet. If the battery is installed in a storied building, the load requirements should be inquired from the construction department. Where anti-quake intensity is more than 7 degree, a quakeproof shelf should be used and it should be fixed with ground bolt in order to diffuse the stress.

3. The VRLA batteries have been filled with electrolyte and charged before delivery, therefore, during installation and transportation, please handle the batteries with care and make sure that safety valve isn’t loosened and that there is no short circuit.



4. The battery pack should be installed near the load and cables, copper busbars and connecting wires should meet the requirements in order to avoid excessive line drop. Voltage drops of multiple parallel lines should be kept consistent with each other as much as possible. Fuse should be equipped for each battery pack.

5. The voltage of battery pack is high voltage, so it involves a danger of electric shock. Use insulation tools and wear protection gloves when connecting or disconnecting cables, copper busbars and connection wires.

6. During installation, connection terminals of cables, copper busbars and battery output end should be kept clean and connected tightly; otherwise, it will lead to a high temperature of terminal and even to spark/fire. Stainless steel bolts, tinned copper busbars, flat washer are used to interconnect batteries; the bolts should be fastened tightly (the torque should be no less than 15 N·m).

Installation Mode Three installation modes are available for GFM battery:

Installation with single-layer vertical rack

Installation with double-layer vertical rack

Installation with three-layer vertical rack/cabinet

Select an installation mode according to Table 5.

T AB L E 5 I N S T AL L AT I O N M O D E S E L E C T I O N

Type Installation Mode Dimension (L× W× H) (mm)

Weight (kg)

Remark

Installation with three-layer vertical rack/cabinet 825 × 500 × 2000 508

Installation with double-layer vertical rack 771 × 456 × 870 397 48V200Ah

Installation with single-layer vertical rack 1503 × 456 × 351 386




Installation with three-layer vertical rack/cabinet 825 × 500 × 2000 828 48V400Ah

Installation with double-layer vertical rack 1265 × 404 × 870 653

Standard configuration: double-layer rack

Chapter 4 - Installation



Weight (kg)

Remark









Installation with single-layer vertical rack 4990 × 362 × 351 1238 48V800Ah



Installation with single-layer vertical rack 4990 × 432 × 351 1490 48V1000Ah


Standard configuration: two combined double-layer racks


48V1600Ah Installation with single-layer vertical rack 4484 × 884 × 402 3009





Standard configuration: two combined single-layer racks



-

24V300Ah Installation with double-layer vertical rack 497 × 456 × 870 259 -




Weight (kg)

Remark




-



-



-




-




-



-





-



Installation Procedure Installation with Double-/Single-Layer Vertical Rack

To install batteries with double-/single-layer vertical rack

1. Check batteries, installation shelf and their components according to related document (the spare part list or general installation drawing).

2. Check the environmental conditions of installation site, and the user should adjust the site if necessary.

3. Determine the positions of ground bolt holes for the installation rack considering the busbar position and following the installation instructions.

4. Punch the ground bolt holes with punching drill or electric hammer.

5. Fix the rack base to the ground with installation kit and ground bolts.

6. Interconnect the rack base with barrier (barrier pole), semi-circle bolt and washer.

7. Insert the battery bearing beam into the rack base, and fix the beam with bolt and nut.

8. Level the installation rack, and, after that, fasten all the bolts.

9. Install and fix the output terminal components (or insulation base) of the rack.

10. Remove one of the barriers (barrier poles) of the rack, and clean filth on the battery output terminals and connectors.

11. Install the batteries into the installation rack and interconnect them according to the installation diagram.

Caution: Be cautious and make sure that there is no short circuit.

12. Install the barrier (barrier pole), and paste the labels of the batteries serial number.

13. Install and fix the monitor of the battery voltage into the rack.

14. Connect the terminal of the monitors to the terminals of the output copper busbar correspondingly.

15. Measure the voltage of each battery one by one with the monitor and voltmeter, keep a record and analyze the data. Make sure that all cables are connected correctly in well contact.

16. Paste insulation protection label on connectors.

17. Clean the batteries and the rack with soft cloth carefully, and clean up the installation site.



Note: The step 13 ~ 15 should be abridged when the monitor of the battery voltage isn’t configured.

Installation with Three-Layer Vertical Rack/Cabinet

To install batteries with three-layer vertical rack/cabinet

1. Check equipment and parts according to the spare parts list.

2. Remove the barriers on the every layer.

3. Install the batteries into the rack/cabinet and interconnect them following the interconnecting diagrams.

Caution: Be cautious and make sure that there is no short circuit.

4. Fix the barriers and paste the labels of the batteries serial number.

5. Measure the voltage of each battery one by one with the monitor and voltmeter, keep a record and analyze the data. Make sure that all cables are connected correctly in well contact.

6. Paste insulation protection label on connector.

7. Clean up the installation sire.

Installation Diagram This section provides the installation diagrams for a part of types for reference.

The relation between battery type and installation diagram is listed in Table 6.

T AB L E 6 R E L AT I O N B E T W E E N B AT T E R Y T Y P E AN D I N S T AL L AT I O N D I A G R AM

Type Single-Layer Vertical Rack

Double-Layer Vertical Rack

Three-Layer Vertical Rack

48V200Ah Figure 8 Figure 14 Figure 4







Type Single-Layer Vertical Rack

Double-Layer Vertical Rack

Three-Layer Vertical Rack

48V800Ah Figure 11 Figure 17 -







1. Installation with three-layer vertical rack/cabinet for 48V200Ah ~ 48V400Ah:

F I G U R E 4 IN S T AL L AT I O N I N TH R E E -L AY E R V E R T I C AL R A C K /C AB I N E T F O R 48V200AH ~ 48V400AH



2. Installation in three-layer vertical rack/cabinet for 48V500Ah:

F I G U R E 5 IN S T AL L AT I O N I N TH R E E -L AY E R V E R T I C AL R A C K /C AB I N E T F O R 48V500AH

3. Installation in three-layer vertical rack/cabinet for 48V600Ah:

F I G U R E 6 IN S T AL L AT I O N I N TH R E E -L AY E R V E R T I C AL R A C K /C AB I N E T F O R 48V600AH



4. Installation in three-layer vertical rack/cabinet for 24V800Ah ~ 24V1000Ah:

F I G U R E 7 IN S T AL L AT I O N I N TH R E E -L AY E R V E R T I C AL R A C K /C AB I N E T F O R 24V800AH ~ 24V1000AH

H

5. Installation in single-layer vertical rack/cabinet for 48V200Ah ~ 48V300Ah:

F I G U R E 8 IN S T AL L AT I O N I N S I N G L E -L AY E R V E R T I C AL R AC K /C AB I N E T F O R 48V200AH ~ 48V300AH

Type L W H48V200Ah

48V300Ah

1503

1875

456

456

351

351




F I G U R E 9 IN S T AL L AT I O N I N S I N G L E -L AY E R V E R T I C AL R AC K /C AB I N E T F O R 48V400AH ~ 48V500AH

Type

48V400Ah

48V500Ah

L

2495

2495 466

404

W H

351

351

7. Installation in single-layer vertical rack/cabinet for 48V600Ah

F I G U R E 10 I N S T AL L AT I O N I N S I N G L E -L AY E R V E R T I C AL R AC K /C AB I N E T F O R 48V600AH




F I G U R E 11 I N S T AL L AT I O N I N S I N G L E -L AY E R V E R T I C AL R AC K /C AB I N E T F O R 48V800AH ~ 48V1000AH

351362499048V800Ah351432499048V1000Ah

HWLType

HL WType

2495 964 35148V1000Ah48V800Ah 3512495 824



9. Installation in single-layer vertical rack/cabinet for 48V1600Ah:

F I G U R E 12 I N S T AL L AT I O N I N S I N G L E -L AY E R V E R T I C AL R AC K /C AB I N E T F O R 48V1600 AH


F I G U R E 13 I N S T AL L AT I O N I N S I N G L E -L AY E R V E R T I C AL R AC K /C AB I N E T F O R 48V2000 AH ~ 48V3000AH

22302230

48V3000Ah48V2000Ah

Type

15041064

WL

402402

H



11. Installation in double-layer vertical rack/cabinet for 48V200Ah ~ 48V300Ah:

F I G U R E 14 I N S T AL L AT I O N I N D O U B L E -L AY E R V E R T I C AL R AC K /C AB I N E T F O R 48V200 AH ~ 48V300AH





13. Installation in double-layer vertical rack/cabinet for 48V600Ah:

F I G U R E 16 I N S T AL L AT I O N I N D O U B L E -L AY E R V E R T I C AL R AC K /C AB I N E T F O R 48V600 AH






F I G U R E 18 I N S T AL L AT I O N I N D O U B L E -L AY E R V E R T I C AL R AC K / C AB I N E T F O R 48V1600 AH








F I G U R E 21 I N S T AL L AT I O N I N S I N G L E -L AY E R V E R T I C AL R AC K /C AB I N E T F O R 24V800AH ~ 24V1000AH

Type L W H24V800Ah24V1000Ah

24952495

362432

351351





24V1000Ah 1265 432 870

Type L W24V800Ah 1265 362

H870

Check after Installation After installation, check carefully the total voltage of the battery pack, the open circuit voltage of o, positive and negative polarity, the equalized/float charging current, the resistance between the output terminal and the cabinet/rack. Make sure that the batteries are installed correctly.

Before connecting batteries to charger or load, make sure that the circuit switch is off. Make sure that they are interconnected correctly, that is, the positive polarity of battery is connected to the positive polarity of charger, and the negative polarity of battery is connected to the negative polarity of charger.

The check items after installation are listed in Table 7.



T AB L E 7 C H E C K I T E M S AF T E R I N S T AL L AT I O N

S/N Item Conclusion

1 All bolts, nuts and screws are fastened tightly and properly with no lack of flat washers and spring washers. Pass Fail

2 The vertical obliquity of the vertical cabinet/rack should be less than 5°. Pass Fail

3 All batteries are clean and neat free from filth or any redundant material. Pass Fail

4 There is no appearance damage for batteries. Pass Fail

5 The total voltage of the battery pack and the open circuit voltage of single battery are normal. Pass Fail

6 The equalized/float charging current of the battery pack is normal. Pass Fail

7 Over temperature doesn’t occur on connecting parts and terminal. Pass Fail


C h a p t e r 5

Operation and Maintenance

In this chapter, you will learn about: Operations of GFM battery

Routine maintenance of GFM battery

Troubleshooting of GFM battery

Operation Operation Precautions 1. Be cautious and make sure that no batteries are short-circuited.

2. Battery must be charged before use.

3. Safety valve cannot be opened.

4. Batteries should be kept clean.

5. Batteries should be charged periodically during a long storage period.

6. Batteries should not serve as a power supply if they are not recharged after accidental discharge.

7. Batteries of different rated capacity cannot be connected in parallel to serve as a power supply.

Charge There are two charge modes for batteries: float charge and equalized charge.

Float charge: When battery has been fully charged, the charging will not stop charging and will be still charging battery with a constant float charge voltage and small float charge current. The battery will be discharged naturally if the charger stops working; float charge serves to the supplement the energy loss.



Equalized Charge: The charger charges battery in a short time with set charge current and set charge time. During battery maintenance, equalized charge is usually used. The charge mode is helpful to activate the chemical characteristics of battery.

T AB L E 8 C H A R G E P AR AM E T E R S

Charging Mode Parameter Float

Charge Equalized Charge

Remark

Charging voltage 2.23 V/cell 2.35 V/cell The voltages are average voltages between positive terminal and negative terminal measured at 25°C.

Max. charging current (A) 0.10C10 0.10C10 -

Temperature compensation coefficient

3 mV/°C 3 mV/°C

If the temperature is out of the range: 20°C ~ 30°C, the float charging voltage falls 3 mV when temperature rises 1°C; the float charging voltage rises 3 mV when the temperature falls 1°C.

The precondition of equalized charge:

The batteries should be charged before first use. The batteries will switch to float charging mode when the equalized charging current is less than 10 mA/Ah, and the float charge time is no less than 24 hours.

During service, the batteries will switch to equalized charging mode when the float charging voltage of single battery is less than 2.18 V. The equalized charge time is within the range: 8 hours ~ 10 hours. Batteries should be recharged periodically if power supply is in bad condition and the power is cut frequently.

Equalized charge should be done when there is any inferior battery. An inferior battery refers to a single battery whose final voltage is less than 1.80 V after 5-hour discharge with a discharging current of 0.10C10.

After accidental discharge and regular capacity detection, equalized charge should be done. The capacity to be charged should be no less than 120% of discharged capacity.

Chapter 5 - Operation and Maintenance


Capacity Detection

Checkpoint: Equalized charge should be done before capacity detection.

1. If the float charging current is 1 mA/Ah ~ 2 mA/Ah, and it remains a stable value for 2 ~ 3 hours continuously after equalized charge switches to float charge, it indicates that batteries have been fully charged. Only if float charge goes on 24 hours and the power has been cut off for over 1 hour, capacity detection can be carried out.

The capacity detection criteria are listed in Table 9.

T AB L E 9 C AP AC I T Y D E T E C T I O N C R I T E R I A

Discharge Rate

Discharging Current (A)

Final Voltage (V/cell)

Capacity Detection Criterion

10 h 1.0I10 1.80 ≥ 1.00C10

5 h 1.6I10 1.80 ≥ 0.80C10

3 h 2.5I10 1.80 ≥ 0.75C10

1 h 5.5I10 1.75 ≥ 0.55C10

In Table 9, I10 is the discharging current with the discharge rate of 10h, and I10 equals 0.10C10.

When batteries are connected in parallel, the rated capacity is the sum of all paralleled batteries.

Caution: The voltage of single battery should not falls to the final voltages listed in Table 9.

2. Batteries should be recharged within 8 hours after discharge; the charging mode will automatically switch to float charging mode when the equalized current is less than 10 mA/Ah. If the float charging current is 1 mA/Ah ~ 2 mA/Ah, and it remains a stable value for 2 ~ 3 hours continuously after equalized charge switches to float charge, it indicates that batteries have been fully charged. After that, float charging mode should last over 24 hours.



Discharge Three ways are available to control discharge depth:

To control discharge depth by discharge time: The product of discharge time and load current should be no more than 0.80C10 (Ah).

To control discharge depth by discharge capacity: The discharge capacity should be set no more than 0.80C10 (Ah).

To control discharge depth by final voltage: to avoid overdischarge by setting partial-load cutoff voltage and full-load cutoff voltage.

Parameter of Switch Power Supply The parameters of switch power supply to control batteries should be set according to load current.

The partial-load cutoff voltage and the full-load cutoff voltage should be set following Table 10.

T AB L E 10 P AR T I AL - /FU L L -LO AD C U T O F F V O L T AG E

Partial-Load Cutoff Voltage (V) Full-Load Cutoff Voltage (V) Ratio of Load Current to I10 Single Battery Battery Pack Single Battery Battery Pack

6/6 1.90 45.6 1.88 45.0

5/6 1.95 46.8 1.93 46.3

2/3 1.96 47.0 1.94 46.5

1/2 1.97 47.3 1.95 46.8

1/3 1.98 47.5 1.96 47.0

1/6 1.98 47.5 1.96 47.0

Other related parameters of switch power supply should be set following Table 11.

T AB L E 11 P AR AM E T E R S O F S W I T C H P O W E R S U P P L Y

Item Specs Parameter

Float charging voltage 2.20 V ~ 2.27 V 2.23 V/cell

Equalized charging voltage 2.30 V ~ 2.35 V 2.35 V/cell

Charge current limiting 0.10C10 (A) 0.10C10 (A)

Upper voltage alarm threshold 57V 57 V

Lower voltage alarm threshold 45V 45 V



Item Specs Parameter

Temperature compensation coefficient of battery

5.5 mV/cell 3 mV/cell

Battery over temperature 35°C 35°C

LVDS Deviation Voltage 44 V 44 V

LVDS Reposition Voltage 47 V 47 V

Equalized charge period 720 h 6 months usually for batteries in equipment room

Periodical equalized charge time 1 h ~10 h 10 h

Precondition of equalized charge when mains recovers

- Equalized charge mode is started as soon as mains recovers

Precondition of float charge switching to equalized charge

≥ 50 mA/Ah ≥ 50 mA/Ah

Equalized charge time with power cut 1 h ~10 h 10 h

Precondition to exit equalized charge ≤ 5 mA/Ah ≤ 5 mA/Ah

Capacity setting for battery diffluence

According to battery capacity According to battery capacity

Batteries connection Serial first, parallel next Serial first, parallel next

Specification for the battery service life ends < 80% of rated capacity < 80% of rated capacity

Voltage difference between individual batteries

50 mV for working mode 20 mV for open circuit mode

50 mV for working mode 20 mV for open circuit mode

Note:

When the environment temperature is out of the range: 20°C ~ 30°C, the float charging voltage and the equalized charging voltage should be compensated following Table 11.

Where mains supply is in good condition and the temperature is always relatively high, the temperature compensation function isn’t enabled; the equalized voltage should be set 2.35 V/cell.

Table 11 is applicable for situation with discharge current less than 0.1C10 (A).



Requirements for Application with Power Cut Battery cannot be used to supply power if power fails again and

battery hasn’t been fully charged according to the requirements after accidental discharge

The float charge time should be no less than 24 hours after equalized charge switches to float charge and the accumulated discharge capacity for power failure once is 50% ~ 80% of the rated capacity.

The float charge time should be no less than 12 hours after equalized charge switches to float charge and the accumulated discharge capacity for power failure for several times is less than 50% of the rated capacity.

If the power supply is in good condition, batteries should be discharged for protection once each 6 months, and the discharge depth should be 50%. Batteries should be fully charged in time after the discharge.

Diesel generator or other auxiliary power device should be equipped if power failure is frequent and failure duration time is long. Diesel generator or other auxiliary power device should be started to power load equipment and charge batteries in time if battery discharge depth is over 80% and mains supply hasn’t recovered.

Battery Replacement If the voltage of single battery is less than 1.8 V (the discharge rate for

one hour is 1.75 V/cell) before 80% of battery capacity is discharged (the capacity corresponding to discharge rate, such as C10 and C3), battery should be replaced.

Replace battery before its service life ends considering the factors, such as environment condition, and environment temperature.



Routine Maintenance Battery should be checked and maintained periodically to prong its service life. The periodical maintenance includes monthly maintenance, quarterly maintenance and annual maintenance.

The check items are listed in Table 12.

T AB L E 12 P E R I O D I C AL C H E C K I T E M S

Period Item Description Requirement and Base Value Maintenance

Total float charging voltage

To detect the total voltage of the battery pack

The total voltage equals the product of cell voltage and batteries number.

Correct the deviation and adjust it to the base value.

To check battery shell and plate for electrolyte flowing out, expansion and damage.

The appearance should be neat.

Troubleshoot and replace faulty parts if necessary.

To check whether it is free from dust and filth.

The appearance should be clean.

Use wet cloth to clean the appearance. Battery

appearance To check the vertical installation rack/cabinet, connecting cables, positive/negative terminal for rust

They should be all free from rust.

If there’s any rust, remove the rust, replace connecting cables, and spread antirust on them.

Connection To check whether bolts and nuts are tight

Bolts and nuts should be fastened tightly.

Fasten the loosened bolts or nuts.

Month

DC power switching

To cut AC power and to switch to DC power

AC power can switch to DC power smoothly.

Correct the possible deviation.

Quarter

Floating charging voltage of single battery

To detect the voltage of each single battery

The float charging voltage with temperature compensation is ±50 mV.

If it is beyond the base value, discharge battery, switch to equalized charge, and then switch to float charge. Check it for 1 ~ 2 months, and replace battery in time if it is still beyond the base value.

Year Discharge test

To cut AC power and discharge battery with discharge current of 0.1C10 (A) and with final voltage set 1.80 V/cell.

The total discharge time should be over 8 hours.

Recharge battery in time if the discharge time is less than 8 hours; after that, if the discharge time is still less 8 hours, it indicates that battery service life ends.



Troubleshooting Common troubles and their solutions are listed in Table 13.

T AB L E 13 C O M M O N TR O U B L E S AN D S O L U T I O N S

Symptom Cause Solution

In the initial stage of operation, one cell voltage and the total voltage fall rapidly when discharging.

The connecting bolts of battery terminal are loosened, or there is filth on terminals or connecting ends of cable, and as a result, the line drop is increased.

Fasten loosened bolts, remove filth, and re-install bolts.

In the initial stage of operation, battery can be discharged normally, but its load is cut off soon.

The load cutoff voltage set through battery managing device (e.g. switch power supply) is too high.

Adjust the load cutoff voltage within the range: 1.85 V/cell ~ 1.98 V/cell.

The real value of total voltage is 4 V less than calculated value.

One cell is connected in reverse. Correct the connection. In addition, the cell should be deeply discharge and then charged. After that, if the cell capacity cannot recover, replace it in time.

In the initial stage of operation, there are differences between cell voltages.

The possible cause is the minute difference between cell’s internal structure and that during transportation.

The cell voltage will be consistent with each other after normal float charging for 3 months.


A p p e n d i x A

Selection, Transportation and Storage

This appendix introduces type selection, transportation requirements and storage requirements.

Type Selection The following items should be considered in battery type selection:

Battery use frequency.

Battery discharging current.

Battery discharge time.

The capacity should be relatively higher, to avoid battery damaged because of over discharge and discharging with ultra current.

Caution: The discharging current should be less than 0.1C10 (A) during discharging.

Transportation The transportation requirements are described as follows,

During transportation, terminal should be protection well, the coping of battery cannot suffer pressure, safety valve cannot be loosened, and short circuit is prohibited.

During transportation, batter should be vertical instead of being upside down, and battery should be handled with care, free from rolling, being thrown, bump, exposure to sunshine and rain.



Storage The storage requirements are described as follows,

The storage temperature is 0 ~ 35°C, and the storage period is usually 3 ~ 6 months. Battery should be charged if its storage time is beyond 3 ~ 6 months.

Batteries should be kept in a dry, clean and ventilated environment free from radiation, organic solvent, corrosive gas, flammable article, fire and exposure to sunlight.

Batteries should be vertical, the coping of battery cannot suffer pressure, and safety valve cannot be loosened. Batteries not packed in wooden boxes cannot be piled.


A p p e n d i x B

Technical Characteristics

This appendix introduces the technical characteristics of GFM series battery.

Discharge Characteristic Discharge Characteristic Curve The discharge characteristic curve is shown in Figure 23.

Figure 23 is the discharge characteristic curve when the temperature is 25°C and the constant discharging current is 0.1C10 (A) ~ 1.0C10 (A). The end of each curve is a final voltage.

F I G U R E 23 D I S C H AR G E C H A R AC T E R I S T I C C U R V E

Discharge time



Discharge Current The discharge current corresponding to discharge rate is shown in Table 14.

T AB L E 14 D I S C H AR G E C U R R E N T C O R R E S P O N D I N G T O D I S C H AR G E R AT E

Discharge Current (A) with Different Discharge Rate

C10 C5 C3 C1 C0.5 Type

Vt=1.80V/cell Vt=1.80V/cell Vt=1.80V/cell Vt=1.75V/cell Vt=1.75V/cell

GFM-200 20 32 50 110 200

GFM-300 30 48 75 165 300

GFM-400 40 64 100 220 400

GFM-500 50 80 125 275 500

GFM-600 60 96 150 330 600

GFM-800 80 128 200 440 800

GFM-1000 100 160 250 550 1000

GFM-1600 160 256 400 880 1600

GFM-2000 200 320 500 1100 2000

GFM-3000 300 480 750 1650 3000

Note: The values in the table are those measured at the temperature of 25°C.

Relation between Discharge Capacity and Temperature The relation between discharge capacity and temperature is shown in Figure 24.

F I G U R E 24 R E L AT I O N B E T W E E N D I S C H AR G E C AP AC I T Y AN D TE M P E R AT U R E

Appendix B - Technical Characteristics


Charge Characteristic The equalized charge time and current corresponding to discharge depth is shown in Table 15.

T AB L E 15 TH E E Q U AL I Z E D C H AR G E T I M E AN D C U R R E N T C O R R E S P O N D I N G T O D I S C H AR G E D E P T H

Discharge Depth (%)

Charging Current (A)

Constant Charging Voltage (V)

Charge time (h)

20 0.10C10 2.35 12

50 0.10C10 2.35 18

80 0.10C10 2.35 22

100 0.10C10 2.35 26

Lifetime Characteristic Discharge Depth Effect on Lifetime The relation between discharge depth and cycle life is shown in Figure 25.

F I G U R E 25 R E L AT I O N B E T W E E N D I S C H AR G E D E P T H AN D C Y C L E L I F E



Working Temperature Effect on Lifetime The relation between the working temperature and lifetime is shown in Figure 26.

F I G U R E 26 R E L AT I O N B E T W E E N W O R K I N G TE M P E R AT U R E AN D L I F E T I M E

Battery can have a long service lifetime and good features when the environment temperature is within the range: 24°C ~ 25°C. The charging efficiency and features will be inferior when the environment temperature is below 25°C; the service lifetime will be shortened when the temperature is over 25°C.

The relation between lifetime reducing percent and environment temperature is shown in Table 16.

T AB L E 16 R E L AT I O N B E T W E E N L I F E T I M E R E D U C I N G PE R C E N T AN D E N V I R O N M E N T TE M P E R AT U R E

Environment Temperature (°C) Lifetime Reducing Percent (%)

25 0

30 30

35 50

40 66

45 75

50 83


Figures

Figure 1 Model Definition.............................................................................15 Figure 2 Appearance of GFM Battery .............................................................19 Figure 3 Chemical Reaction of Charging/Discharging .......................................20 Figure 4 Installation in Three-Layer Vertical Rack/Cabinet for 48V200Ah ~

48V400Ah .........................................................................................27 Figure 5 Installation in Three-Layer Vertical Rack/Cabinet for 48V500Ah ............28 Figure 6 Installation in Three-Layer Vertical Rack/Cabinet for 48V600Ah ............28 Figure 7 Installation in Three-Layer Vertical Rack/Cabinet for 24V800Ah ~

24V1000Ah........................................................................................29 Figure 8 Installation in Single-Layer Vertical Rack/Cabinet for 48V200Ah ~

48V300Ah .........................................................................................29 Figure 9 Installation in Single-Layer Vertical Rack/Cabinet for 48V400Ah ~

48V500Ah .........................................................................................30 Figure 10 Installation in Single-Layer Vertical Rack/Cabinet for 48V600Ah..........30 Figure 11 Installation in Single-Layer Vertical Rack/Cabinet for 48V800Ah ~

48V1000Ah........................................................................................31 Figure 12 Installation in Single-Layer Vertical Rack/Cabinet for 48V1600Ah ........32 Figure 13 Installation in Single-Layer Vertical Rack/Cabinet for 48V2000Ah ~

48V3000Ah........................................................................................32 Figure 14 Installation in Double-Layer Vertical Rack/Cabinet for 48V200Ah ~

48V300Ah .........................................................................................33 Figure 15 Installation in Double-Layer Vertical Rack/Cabinet for 48V400Ah ~

48V500Ah .........................................................................................33 Figure 16 Installation in Double-Layer Vertical Rack/Cabinet for 48V600Ah.........34 Figure 17 Installation in Double-Layer Vertical Rack/Cabinet for 48V800Ah ~

48V1000Ah........................................................................................34 Figure 18 Installation in Double-Layer Vertical Rack/cabinet for 48V1600Ah .......35 Figure 19 Installation in Double-Layer Vertical Rack/cabinet for 48V2000Ah .......35 Figure 20 Installation in Double-Layer Vertical Rack/cabinet for 48V3000Ah .......36 Figure 21 Installation in Single-Layer Vertical Rack/Cabinet for 24V800Ah ~

24V1000Ah........................................................................................36 Figure 22 Installation in Double-Layer Vertical Rack/Cabinet for 24V800Ah ~

24V1000Ah........................................................................................37 Figure 23 Discharge Characteristic Curve.......................................................49 Figure 24 Relation between Discharge Capacity and Temperature .....................50 Figure 25 Relation between Discharge Depth and Cycle Life..............................51 Figure 26 Relation between Working Temperature and Lifetime ........................52





Tables

Table 1 Typographical Conventions................................................................ x Table 2 Mouse Operation Conventions............................................................ x Table 3 Safety Signs....................................................................................xi Table 4 Technical Specifications ...................................................................17 Table 5 Installation Mode Selection...............................................................22 Table 6 Relation between Battery Type and Installation Diagram.......................26 Table 7 Check Items after Installation ...........................................................38 Table 8 Charge Parameters .........................................................................40 Table 9 Capacity Detection Criteria ...............................................................41 Table 10 Partial-/Full-Load Cutoff Voltage ......................................................42 Table 11 Parameters of Switch Power Supply .................................................42 Table 12 Periodical Check Items...................................................................45 Table 13 Common Troubles and Solutions......................................................46 Table 14 Discharge Current Corresponding to Discharge Rate ...........................50 Table 15 The Equalized Charge time and Current Corresponding to Discharge

Depth ...............................................................................................51 Table 16 Relation between Lifetime Reducing Percent and Environment

Temperature ......................................................................................52

Documents

Installation Procedure of Battery Bank