GFX Series Acid-proof BatteryOPzS

Users ManualC

Shuangdeng Group Fuste Power Supply Co., Ltd

GFX Series Acid-proof BatteryOPzS

Users ManualC

Information Edition
20051212-R1.0
Product Edition
V1.0

Scheming: Fuste Power Supply Co., Ltd Technical Department

Compilation: Xu Dongming
Correction: Lu Wangzhen
Correction: Lu wangzhen
Auditing: Lu Yashan
Testing:
*

Yu Shiyang Yu Shiyong
*

Shuangdeng Group Fuste Power Supply Co., Ltd

Address: Shuangdeng Science and Technology Park, Taizhou, Jiangsu
Postcode225526
Websitehttp://www. Shuangdeng. com. cn/
Servicet Hotline05238529806 8529885 4008-899-886
Fax05238912370
E-mailfuste@shuangdeng.com.cn
*

Nofuste20051111

Statement
The copyright of this document only belongs to Shuangdeng
GroupShuangdeng Power Supply Co., Ltd. Any excerpt, copy or
translation is prohibited without the written permission of the writer.
All rights reserved.

The trademark above is the registered trademark of Shuangdeng

Group. The product name and symbol of Shuangdeng Group is the special
symbol or registered trademark of Shuangdeng Group. The other product
or company name mentioned in this manual may be the trademark or name
of the relative owners. Without any prior written permission of
Shuangdeng Group or the third party owners of the trademark or name,
any readers of this manual cant apply the symbol used in this manual by
any way since no license or right has been granted.
The designs of this product comply with the requirements concerning
environment protection and human safety. The storage, usage and discard of this
product should be done according to the product manual, relative contract or the
legal requirements of the relative countries.
Since the product and technologies are being improved or promoted
continuously, then the information in this manual may not be completely
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For the latest information about the products or manuals, please dial the
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GFX Series Acid-proof Battery (OPzS) Users Manual

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Foreword
Manual Description
GFX Series Acid-proof Battery (OPzS) is the product of Shuangdeng Group. GFX
Series Acid-proof Battery (OPzS) Users Manual is the manual accompanied with the battery.
Please read the manual carefully in advance.

Introduction
GFX Series Acid-proof Battery (OPzS) Users Manual introduces the technical parameter,
principle, installation dimension and method, and maintenance.
Chapter 1 Safety Instruction, some operation precautions for battery installation, operation,
and maintenance.
Chapter 2: Summary Introduce the type, component name and product specification and
main parameter about GFX
Chapter 3 Outline and structure, the outline, structure character and working principle of GFX
Chapter 4 Installation about the installation mode, installation mode and the installation
diagram of some types.
Chapter 5 this chapter is mainly about the Initial charge, operation and maintenance of the
battery. This chapter introduces about the initial charge, operation method and
maintenance precautions.
Appendix A: Type selection, transportation and storage, about how to choose the type, what to
notice in the delivery and storage
Appendix B: technical speciality, introduction about the discharge character, and charge
character, the life character.
Appendix C the mixing, perfusion, checking and adjustment of electrolyte,
Description to the symbols used in this manual:
We apply four eye-catching marks to show the special noticed points in operating.
notice
operation precautions.

caution

warning

danger:

show the special

Content
Chapter 1 Safety Instruction
1.1 Safety signs

1-1

1.2 Safety issues1-1

2-1

Chapter 2 Abstract

2.1 Type introduction 2-1

2.2 Component title

2-1

2.3 product specification and main parameter 2-2

Chapter 3 outline and structure

3-1

3.1 outline 3-1

3.2 structure character

3-1

Chapter 4 Installation
4.1 check about the installation site

4-1

4-1

4.2 Precaution 4-1

4.3 Installation mode
4.4 Installation procedure

4-3

4.4.1 single vertical rack installation procedure

4.5 Installation diagram

4-2

4-3

4-7

4.6 check after installation

4-8

chapter 5 initial charge, operation and maintenance

5-1

5.1

5-1

Initial charge of GFX

5-1
5.1.1 precaution and preparation before initial charge
5.1.2 Initial charge mode 5-1
5.1.3 the precaution and common sense
-i-

5-2

5.2 operation

5-2

5.2.1 operation system

5-2

5.3 Maintenance

5-4

5.3.1 Maintenance issue

5-4

5.3.4 Equalized Charde Mode

5-5

5.3.5 when to equalized charge

5-6

5.3.6.the operation requirement for the time cut-off

5-6

5.3.7 the examining and maintenance list of battery

5-7

5.4 troubleshooting

5-8

Appendix A Type selection, Transportation and Storage

A-1

A 1 Type Seletion

A-1

A.2 Transportation

A-1

A 3 Storage

A-1

Appendix B Technical Character

B-1

B.1 Discharge Character

B-1

B.1.1 Discharge Curve

B-1

B.1.2 Discharge current and capacity

B-1

B.2

charge character B-2

B.3 life Character

B-3

B.4 capacity character

B-3

B.4.1 the relation curve between discharge capacity and temperature

B-3

B.5 the relation curve between charge voltage and temperature

B-4

Appendix C the mixing, perfusion, observation and adjustment of electrolyteC-1

C.1 the mixing procedure of electrolyteC-5
C.1.1 preparations
C.1.2 technical requirement of density sulfric and pure water

C-5

C-6
C-6

C.1.3 the mixing of electrolyte

C.1.4 perfusion of electrolyte

C-7

C.1.5 observation and adjustment of electrolyte

C-8

-ii-

Diagram content
Diagram 2.1-1

definition of GFX-200

2-1

Diagram 2.2-1

the visual part name of GFX-1000

2-1

Diagram 3.1-1

the outline diagram of GFX

3-3-1

Diagram 4.4-2

the name of the vertical rack of GFX-200/48V

4-4

Diagram 4.5-1

single vertical installation rack of GFX-200/48V~ GFX-600/48V

4-7

Diagram 4.5-2

single vertical installation rack of GFX-800/48V~ GFX-1500/48V

4-8

Diagram 4.5-3

ingle vertical installation rack ofGFX-2000/48V~ GFX-3500/48V

4-8

Diagram A.2-1

the suspending diagram of battery

A-2

Diagram B.1-1

discharge character curve under different rates

BB-1

DiagramB.2-1

the

curve

changed

with

time

under

different

equalized

charge

voltages,

currents,electricities

B-2

Diagram B.3-1

the relation curve between operation temperature and life

B-3

Diagram B.4-1

the relation curve between discharge capacity and temperature

B-3

Diagram B.5-1

the relation curve between charge voltage and temperature

B-4

-i-

Table content
Table 1.1-1 definition of safety signs

1-1

table 2.3-1

the list of product specification and main parameter

2-2

table 4.3-1

the selection list of installation modes

4-2

Table 4.4-1

the quantity list of the spare parts of the vertical rack

4-3

Table 4.5-1

the instruction figure of installation diagram

4-4-7

Table 4.6-1

the checking items list after installation

4-8

Table 5.2-1

the list of charge parameter

5-12

Table 5.2-2

the cut-off voltage settings of switch power

5-12

Table 5.2-3

the related parameter setting of switch power

5-12

Table 5.3-1 standard for capacity check

5-5

Table 5.3-2 periodical examining items list

5-16

Table 5.4-1 common troubleshooting

5-8

Table B.1-2 discharge current list under different discharge rates

B-2

-i-

Chapter 1 Safety Instruction

1.1 Abstract
This chapter introduces about the safety signs and the precautions. Please carefully read it before operation
to ensure safety.

1.1 Safety Signs

The safety signs indicate the safety issues that should be conformed to in installation, operation and
maintenance. The safety signs are shown as following figure 1.1-1

Figure 1.1-1 Safety Signs and Meanings

Safety Signs

Meaning
Safety Notice
Electric Shock

1.2 Precautions
Before any operation of the equipment, please carefully read all the safety instructions in this manual
to avoid personal injury or equipment damage.
Shuangdeng Group bears no liability to the consequences incurred by violation of the general safety
operation requirement, or violation of the safety standards for designing, manufacturing and using the
equipment.
1.

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

2.

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

3.

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

4.

Do use special tools.

Do use special tools, instead of common tools during electrical connections. In addition, keep
the tools in good insulation condition (e.g. wrap insulating tape around the bare metal parts)

1-1

before using them to avoid short circuit and personal injury caused by tool contact with any
live objects.
5.

Using the batteries of the same model

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

6.

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.

7.

Acid-corrosion danger
No great impact shack and dumpage the battery when handling and operating. Otherwise, it
may cause the leakage of the acid.
On mixing the acid, please wear the protections: face-guard, acid-proof shoes, acid-proof glove,
acid-proof clothes, eye-protector.
Never have the acid spill on skin, eyes without any protections, also no acid on equipment or
floor.

8.

Operation regulation
Before battery operation, read the safety precaution/instruction, and the operation instructions,
especially the battery interconnection instructions.
Substandard operation 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.

9. The Operation Environment

The battery should be kept far away from fire, organic solution; avoid direct sunshine and the
temperature should be the same of the same set.

-1-2-

Chapter 2 summary
Abstract
This chapter introduces about the type, component name of GFX, product specification,
the main parameter.

2.1 Model Introduction

GFX Series Acid-proof Battery, also called flooded battery (shortly called GFX flooded
battery), is the product of Shuangdeng. The manufacture license number QS:XK
06-044-00398. The GFX battery is of single cell, each voltage is 2V. Take GFX-200 as an
example, the model meaning is shown in Figure 2.1-1.

GFX-200
S e r ie s A c id p ro o f B a tte ry

R a te d c a p a c ity
C 1 0 u n it:A h

Figure 2.1-1 type and definition of GFX-200 Flooded battery

2.2 visual part of the battery

Choose GFX-1000 as an example

-1-3-

Diagram 2.2-1 the visual parts of GFX-1000 flooded battery

2.3product specification and the main parameter

see the following table2.3-1

figure2.3-1 list of the main parameter and product specification

Battery Type

Nominal

Nominal

voltage

capacity

Ah

Number of the

Outline dimension

weightkg

terminal post of
the same polarity
piece

mm mm mm mm dry

flooded

Acid
weight

GFX-200

200

103

206

354

409

13.5

18.0

4.5

GFX-250

250

124

206

354

409

16.0

21.0

5.0

GFX-300

300

145

206

354

409

19.0

25.0

6.0

GFX-350

350

124

206

470

525

21.5

28.0

6.5

GFX-420

420

145

206

470

525

25.5

33.5

8.0

GFX-500

500

166

206

470

525

29.0

39.0

10.0

GFX-600

600

145

206

645

700

34.0

46.0

12.0

GFX-800

800

191

210

645

700

48.0

64.0

16.0

GFX-1000

1000

233

210

645

700

57.0

77.0

20.0

GFX-1200

1200

275

210

645

700

68.0

92.0

24.0

GFX-1500

1500

275

210

795

850

82.0

112.0

30.0

GFX-2000

2000

399

214

771

826

110.0

150.0

40.0

GFX-2500

2500

487

212

771

826

140.0

190.0

50.0

GFX-3000

3000

576

212

771

826

163.0

225.0

62.0

notethe output terminal is M10screw hole

-1-4-

Chapter 3 outline and structure

Abstract
This chapter introduces the outline, structure and operation principle of GFX battery

3.1 Outline
The GFX batteries consist of positive and negative plate, separator, post, acid-proof
bolt, and transparence the accessories. See figure 3.1-1

0
0
5
3
X
F
G
0
0
5
2
X
F
G

0
0
0
2
X
F
G

GFX200-GFX600

GFX800-GFX1500

Diagram 3.1-1 outline diagram of GFX

3.2 structure character

Positive Plate: tubular plate can prevent the flake of active material. The skeleton was caste with Pb-Antimony alloy, which
has a thin alloy structure, and with good corrosion-proof that greatly prolonged the service life.

Negative plate: the pasted plate with a radioactive structure can greatly improve the utilization ratio of
active material and the discharge ability with a large current, also with strong charge acceptability.

1-1

Separator: with the combination of tiny porous rubber separator and porous PVC ripple separator,
the separator is of high porous and with good corrosion-proof which can improve the
acid-absorbing. This separator can greatly improve the diffusion of electrolyte and reduce the
inner resistance.
Battery container and cover: the blue transparent AS container imported from Italy Plastam
Company is of good corrosion-proof, flame- retardant and strong. Besides, its beautiful
appearance also allows the view of the inner structure of battery.
Terminal: The inner copper lead terminal, weld sealing plus special gelled bond sealing, double
compound to ensure the liability of the terminal.
Acid-proof bolt: the special funnel structure of the bolt ensures the acid filter and flame retardant
function, besides; it can measure the density and temperature of the electrolyte, easy to use and
maintenance.

-1-2-

Chapter 4 Installation
Abstract:
This chapter mainly introduces about the installation mode of GFX battery.

4.1 Examine the Installation Site

1. the best operation temperature: 20
2. The installation site should be dry, clean and ventilate, free of excessive radiation,
infrared ray, organic solvent, corrosive gas and exposure to sunlight.
3.

It is necessary to adjust the density of the acid during operationThe installation

site should have the function of corrosion-proof and drainage.

4. There should have adequate water source in the installation site.

4.2 Precautions
1. According to the customers demand, the GFX battery can be delivered with electrolyte and charge, or
without electrolyte. No dumpage of the battery with electrolyte.
2. Ventilation hole of heater or air conditioner and calorific part of switch power supply should not be
towards the GFX battery. The temperature difference of various parts of the battery should be kept no more
than 3. It is recommended to use an infrared thermal detector to detect the temperature of battery
parts.
3. 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
7degree, a quakeproof shelf should be used and it should be fixed with ground bolt in order to diffuse the
stress.
4. Handle with care of the GFX batter to avoid any impact and pressure. No dust or wasted water flow into
the battery through the valve. No direct connection of red and blue terminals of the same battery to cause
short circuit.
5. The installation should near the load and it is also very important to choose suitable cables, copper bars
and battery connection to ensure the safety operation and avoid increasing of voltage differences.
In the parallel connection of multiple circuitries, try to make all the voltage differences the same, and
install fuse in all the batteries.
1-1

6.

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

7.

During installation, connection terminals of cables, copper bars 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 bars, flat washer are used to interconnect batteries; the
bolts should be fastened tightly(the torque should be about 25Nm).

8.

The battery connection should refer to the requirement strictly, it is never permitted to connect one, or
some batteries without any load to cause short circuit.

9. If the cable of load is prior settled, the output direction of positive and negative terminal should be
correct when installation.
10 Flush the acid if spilled on skin.
11 connect the same polarity of each circuit in parallel connection. Never connect two polarities together.

12. Give enough space for the observation and adjustment of the density of electrolyte.

4.3 Installation Mode

The following modes are available to the GFX battery

See figure 4.3-1

Caution
For those factors that make you couldnt not follow the installation methods-such as
space, groundsill load, output voltage and so on, you can call us for the substandard
solution.

Figure 4.3-1 Installation node selection

Dimension (L*W*H)

Weightkg

Single-layer vertical rack

1640552425

448

Single-layer vertical rack

1892552425

537

Type

Installation mode

GFX-200/48V
GFX-250/48V

-1-2-

Remarks

Dimension (L*W*H)

Weightkg

Single-layer vertical rack

2144552425

622

GFX-350/48V

single-layer vertical rack

1892552515

685

GFX-420/48V

single-layer vertical rack

2144552515

798

GFX-500/48V

single-layer vertical rack

2396552515

904

GFX-600/48V

single-layer vertical rack

2144552600

1118

GFX-800/48V

single-layer vertical rack

1544532600

1507

The

single-layer vertical rack

1544616600

1827

installation rack

GFX-1200/48V

single-layer vertical rack

1544700600

2150

is composed with

GFX-1500/48V

single-layer vertical rack

1544700750

2782

two racks

GFX-2000/48V

single-layer vertical rack

1578532730

4038

The 48v

GFX-2500/48V

single-layer vertical rack

1566620730

4951

installation rack

GFX-3000/48V

single-layer vertical rack

1566708730

5865

is composed with

GFX-3500/48V

single-layer vertical rack

1566708730

6045

two racks

Type

Installation mode

GFX-300/48V

GFX-1000/48V

Remarks

48v

4.4 Installation procedure

4.4.1 Single-layer Vertical Rack Installation Procedure

1.

Before installation, please read this manual to ensure safety. Besides, to make sure that the

installation environment is probable, adjustment can be done if necessary.

2. Check battery and installation shelf according to the spare parts and installation diagram, as
figure 4.4.-1.The spare parts and the substance can refer to the figure 4.4-2.

Figure 4.4-1 Vertical Spare Parts List

quantity of the spare
parts

Bearing
framework

barrier

Bearing
beam

bolt/
washer

Bulge Insulation
bolt

output terminal
Battery Connection

mount

Single layer vertical rack

(24 pieces)

3pieces

2 roots

4roots

32sets

6sets

6pieces

44pieces

23roots

Single layer vertical

rack (12 pieces)

2 pieces

2 roots

4roots

32sets

4sets

4pieces

20pieces

23roots

Single layer vertical

rack (6 pieces)

2pieces

4roots

3roots

22sets

4sets

4pieces

10pieces

23roots

(GFX-200/48V~GFX-600/48V)

(GFX-800/48V~GFX-1500/48V)

(GFX-2000/48V~GFX-3500/48V)

-1-3-

Diagram 4.4-2 title of the spare parts of installation vertical rack GFX-200/48V

3 Connect the insulation basement to the bearing rack with bolt and screw it
tightly pay attention to the direction of the hole
4 Connect the pole with washer and stand.
5 Put the bearing beam on the under layer beam, and connect it with bolt
battery
6 Make sure that the rack is vertical, no loose.
7 Determine the position of installation rack considering the cable position, the
length, width, height and the dimension, and the ambient equipments.

NOTECaution
Leave enough space for the observation and adjustment of the electrolyte density

Mark on the vertical rack about the position of the ground bolt, remove the rack after
ensuring

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

10 Fix the rack base to the ground with ground bolt.

11Remove one of the barriers of the rack after appropriate installation
12Install the output terminal component of the rack and fix it well.

-1-4-

The installation procedure of charged battery with electrolyte differs from that
without electrolyte. As to the installation procedure of flooded battery, please
refer to A13-A23.
A13 According to the installation diagram, place the battery in the vertical rack, taking the interval
between the batteries.

Notice
Pay special attention to the first on shelf battery about its position and polarity. Thus
you can find the oriental of the output terminal to make sure no mistake happen.

A14Choose the appropriate connectors to connect bolt and battery, pay attention to
the colors of different polarity to avoid short circuit.
A15 Check the output voltage of the positive and negative parts to see if it is larger
than 48V after install the batteries, otherwise, you should check about the
short circuit problem. Paste the battery serial number after good installation.
A16 Observe and measure the density and height of the electrolyte to see if it is
right. If not, do some corrections at once. Refer to the second requirement of
section 1.5, in Appendix C to observe and measure the height and density of
the electrolyte.
A17. Install and fix the monitor of the battery voltage into the rack.
A18According to the corresponding signal cable of each monitor, choose the
corresponding battery.
A19 Measure the voltage with monitor and voltage meter, keep records and do
some comparison to make sure that all cables are connected correctly in well
connection.

Note
Omit steps 17-19 if there is no monitor.
A20Do the right insulation mark of the connection.

-1-5-

A21Clean the batteries and the rack with soft cloth carefully, and clean uo the
installation site.
A22According to the manual, to make sure that the relative parameter of the switch
power (see chapter 5). After make sure of the right installation, notify the customer
about the power-on and the following procedures.
A23Enter into the relative procedures for initial charge and initial check.

As to the installation procedure of dry battery, please refer to B13-B25

B13 Open the valve of the battery, perfuse the electrolyte with the density of 1.22
0.002 g/cm320 through the funnel. The height is equal to the electrolyte level
or 1cm higher(refer to Appendix C to finish the perfusion and adjustment of the
electrolyterecommend expert to do it

B14Remove the funnel and fix the valve again. Clean the battery with soft cloth,
and the acid perfusion site to ensure no acid left on the site.
B15According to the installation diagram, place the battery into the rack, pay
attention to the space between batteries. install battery block if necessary
B16Choose the matched connectors to connect bolt and battery, pay attention to the
colors of different polarity to avoid short circuit.
B17Paste insulation protection label on connectors
B18Replace valve with acid-proof bolt. Clean the batteries and the rack with soft
cloth carefully, and clean the installation site.
B19Check to ensure that the reverse polarity of two batteries terminals are
connected, from the appearance that is : red, bluered, bluered

blue---red,

blue. After confirmation, that the operation is permitted.

note
The positive terminal connects with the positive of the charger, negative with
negative.
B20 Initial charge the battery according to Chapter 5.

-1-6-

B21 Do some adjustment according to the Appendix C about the electrolyte height
and density completely meet the requirement.
B22Clean the battery and battery rackmake sure that no acid left on the site.
B23Refer to A17-A19 for those with monitor.
B24According to this manual to set the parameter of the switch power(see chapter
5), do the next procedure after confirmation.
B25Enter into the relative procedure to do some initial checking.

4.5

Installation Chart
This chapter gives some installation chart about some type, for the reference.
Refer to the installation diagram when installing

See 4.5-1
figure4.5-1 installation instruction figure
SPECIFICATION

Single layer vertical

GFX-200/48VGFX-600/48V

Figure 4.5-1

GFX-800/48VGFX-1500/48V

Figure 4.5-2

GFX-2000/48VGFX-3500/48V

Pb

Pb

Pb

0
0
3
X
F
G

Pb

0
0
3
X
F
G

Pb

0
0
3
X
F
G

Pb

0
0
3
X
F
G

0
0
3
X
F
G

0
0
3
X
F
G

Pb

0
0
3
X
F
G

Pb

0
0
3
X
F
G

0
0
3
X
F
G

0
0
3
X
F
G

Pb

0
0
3
X
F
G

0
0
3
X
F
G

Figure4.5-3

Pb

L e n g th o f fra m e w o rk )

L e n g th o f g ro u n d b o lt ho le )
(T o ta l le n g th o f in sta lla tio n rack )

11.
4.5-1GFX-200/48VGFX-600/48Vsingle-layer vertical rack

-1-7-

GFX-200/48V

GFX-250/48V

GFX-300/48V

GFX-350/48V

GFX-420/48V

GFX-500/48V

GFX-600/48V

425

425

425

515

515

515

600

1520

1772

2024

1772

2024

2276

2024

Diagram 4.5-1 GFX-200/48VGFX-600/48V single layer vertical diagram

Pb

Pb

Pb

Pb

Pb

Lengthof framework)

Lengthof framework)

Lengthof groundbolt hole)

Lengthof groundbolt hole)

(Total lengthof installationrack)

(Total lengthof installationrack)

4.5-2. GFX-800/48VGFX-1500/48Vsingle-layer vertical rack

GFX-800/48V

GFX-1000/48V

GFX-1200/48V

GFX-1500/48V

600

600

600

750

462

546

630

630

-1-8-

0
0
0
1
X
F
G

Pb

0
0
0
1
X
F
G

Pb

0
0
0
1
X
F
G

Pb

0
0
0
1
X
F
G

Pb

0
0
0
1
X
F
G

0
0
0
1
X
F
G

0
0
0
1
X
F
G

Pb

0
0
0
1
X
F
G

Pb

0
0
0
1
X
F
G

0
0
0
1
X
F
G

0
0
0
1
X
F
G

0
0
0
1
X
F
G

Pb

Diagram 4.5-2 GFX-800/48VGFX-1500/48Vsingle-layer vertical rack diagram

3 GFX-2000/48V~GFX-3500/48Vsingle-layer vertical rack

Length of framework)

Pb

Pb

0
0
5
2
X
F
G

Pb

0
0
5
2
X
F
G

Pb

0
0
5
2
X
F
G

Pb

0
0
5
2
X
F
G

Pb

0
0
5
2
X
F
G

0
0
5
2
X
F
G

Pb

0
0
5
2
X
F
G

Pb

0
0
5
2
X
F
G

0
0
5
2
X
F
G

Pb

0
0
5
2
X
F
G

0
0
5
2
X
F
G

0
0
5
2
X
F
G

Pb

Pb

Pb

Length of framework)

Length of ground bolt hole)

Length of ground bolt hole)

(Total length of installation rack)

(Total length of installation rack)

GFX-2000/48V

GFX-2500/48V

GFX-3000/48V

GFX-3500/48V

1448

1436

1436

1436

462

550

638

638

Diagram 4.5-3 GFX-2000/48V~GFX-3500/48Vsingle-layer vertical rack diagramfigure GFX-3000battery

4.6 The examination after installation

After installation of the battery, check the record carefully; refer to figure 4.6-1 as to
the main item.
Figure0-1 the checking items list after installation
No

Checking items

Results

The polarities are in right connection, the voltage of the battery

1

group between positive and negative output terminals are higher than

Y N

48V
2

The voltage of each cell in the same battery group is between 2.1
and 2.2V.
-1-9-

Y N

If several battery groups are parallel connection, each output

3

positive terminals should be connected together and negative

Y N

terminals together.
4

The positive and negative output terminals of the battery group

should be connected with the counterparts of the charge device.

Y N

All of the bolts, nuts and screws are fastened tightly.

Y N

All of the bolts, nuts and screws are fastened tightly.

Y N

7
8
9
10

No unnecessary connecting wires or tools etc. are left on the

batteries or racks.
The appearances of the batteries have no cracks or damages.
The safety valve has been twisted tightly and has no looseness or
damage.
The ambient site of the batteries and rack is clean.

Y N
Y N
Y N
Y N

All of the parameters of the battery group, such as the

11

equalization charge and float charge currents, have been set

Y N

correctly.
12

The resistances between output terminals and the rack are normal.

Y N

13

The height and electrolyte density are in a normal range

Y N

14

Other items you think necessary

Y N

15

Y N

16

Y N

17

Y N

18

Y N

-1-10
-

Chapter 5 Initial chargeoperation and

maintenance
Abstract
This chapter introduces about initial charge, operation and maintenance.

5.1

The initial charge of GFX

1 The requirement for the electrolyte:
APrepare with industrial sulfuric and ion-rid water;
BPerfuse with the temperature below 20
2The acid level should be basically equal to the electrolyte level.
3Install the battery with acid into the rack , make sure of the right connection.
4Wring the acid-proof bolt well, cover it well, make sure that no sealed valve wringing
on the vent.
5Clean the battery and rack to make it dry.
6. Prepare with the 1.5 degree electricity meter, and 0.5 degree voltage meter.
7Get the thermometer -10-100and acid densimeter1.200-1.300g/cm3 ready
8Input the charge mode correctly
9Charge the battery after storing the GFX battery with electrolyte for at least 8 hours
till the electrolyte temperature drops below 30.

5.1.2 Initial charge mode

1Constant current charging during the whole process
Fully charge the battery with the current of 0.05C10A for 66 hours
2Constant current charge periodically (first)
Charge the battery for 36 hours with the current of 0.05C10A after 15 hours
charging with the current of 0.1C10A.

-1-11-

3Constant current charge periodically (second )

Charge with the current of 0.1C10A until the terminal voltage of the last battery
rises to 2.4Vthen continue to charge with the current of 0.05C10A for 36hours

5.1.3 Safety issues and common knowledge during initial charge

1Take whole checking after charging begins. Keep the following records per hour
the terminal voltage of each battery, the total voltage, current, the results of the
second battery, and reciprocal second one, the electrolyte density and
temperature of the middle one. Please contact if some abnormal situation occur.
2Control the temperature below 20 while charging in a good ventilation and heat
dispersion surroundings.
3Pay special attention to the electrolyte temperature while approaches 45, its
better to keep it below 40charge with half current amount once exceeds, stop
charging while exceeds 50Recharge after the electrolyte temperature drops
bellows 40The charge current remains the same in the whole process.
4Indications when fully charge with constant current: the terminal voltage and
electrolyte density of each battery remains the same in the following 3 hours,
with large amount air bubble.
5To confirm that no short circuit exist at the beginning of initial charging through
test of voltage.

note 1
No close of the valve in the following cases: after perfusion of electrolyte,
during initial charge and operation; otherwise, it will result in the explosion of the
battery.

Note 2
The formation system of the initial charge couldnt apply in other charge
systems.

-1-12
-

5.2

Operation
5.2.1 Operation system
1Usually in the float charge operation with periodically equalization charge
z

Float charge is one of the charge modes. The charger will still supply
constant float charge voltage and small float charge current to the battery
when the battery is fully charged. Once the charge stops, the battery will
discharge automatically. Through this float charge mode, the self-discharge
can be compensated.

Equalization charge is another charge mode. Fast charge the battery in the prior set
charge current and charge time, to make sure that the battery is fully charged
during operation. Besides, equalization charge is good for the maintenance of
the battery and the chemical activation.
2Charging parameter for float charge and equalization charge.
Charging parameter for float charge, see 5.2-1
Figure 5.2-1 charge parameter list
Charge mode
Parameter

Float charge

Remark

equalization
charge

The even measured value of the

Charge voltage

2.23V/cell

2.35V/cell

positive and negative terminates at

20

Maximum
charge current

0.10C10A

0.10C10A

3mV/

3mV/

Temperature

Refer

compensation

to the charging voltage and

environment curve B-5

coefficient

3Switch power parameter setting

The control parameter of the switch power on the battery set should be according to the
loaded current. The power off voltage setting of the switch power as figure5.2-2 shows,
Figure5.2-2 Voltage setting figure of switch power off once or twice
Loaded current and
I10

Power off voltageV

Cell battery
-1-13-

Battery group

Power off voltageV

Cell battery

Battery group

Power off voltageV

Loaded current and

I10

Power off voltageV

Cell battery

Battery group

Cell battery

Battery group

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

Parameter set of switch power, see figure5.2-3

Figure 5.2-3 switch power parameter setting figure
GFX flooded battery parameter

Items
float charge voltage

2.23V/cell

equalization charge voltage

2.35V/cell

Charge current limit

0.10C10A

upper alarm voltage

57V

Lower alarm voltage

45V

Temperature

compensation

coefficient of battery
Upper temperature limit of the
battery

3 mV/cell
35

LVDS deviation voltage

44 V

LVDS reposition voltage

47V
Six months for the battery used in

equalization charge period

machine room battery

Periodically equalization charge

time
The

precondition

of

the

equalization charge
Conditions

of

float

charge

equalization charge time when

power off
of

Start equalization charge to the batteries

as soon as main electricity recovers

switch to equalization charge

Condition

10h

stopping

equalization charge
Capacity setting of the batteries
for current transforming

-1-14
-

50mA/Ah
10h
20mA/Ah
According to the actual battery capacity

Battery connection
voltage

difference

Series first then parallel

among

batteries

Less than 90mV for loop charge(3

months later)
Less than 20mV for open circuit

note

1 If the environment temperature is out of the range of 20-30, the float charge voltage and the equalization
charge voltage should be compensated according to the regulations in Table 5.1-1.
2. For the district that the main electricity supply is in a good condition and the environment temperature is very
high throughout the year, the equalization voltage should be set at 2.35V/cell if the equipment doesnt have the
temperature compensation function.
3. This table is applicable for the situation that the discharge current is less than 0.10.1C10 A.

5.3

Maintenance
5.3.1 Maintenance
1 The battery should be kept clean and dry. Wring tight the acid-proof bolt, and
cover it.
2 The installation site should be kept clean and dry. With the best temperature
about 20, the battery room should be given a ventilation once weekly.
3 No dust fall in the battery.
4 Clean the acid-bolt every month with pure water to remove the filth.
5. Take a monthly check on the connection to avoid looseness.
6 No organic solution into the battery room, let alone the battery.
7 Take a monthly check on the electrolyte level and density, do some adjustment
when necessary.
8 No puppy enter into the room to avoid the short circuit of the battery.
9 Give periodically supplementary charge to the battery for long storage.
10

For the circumstances that the battery hasnt been made supplementary

charge according to the requirements after accidental discharge, the batteries cant
be used to supply power further if the power fails again.
-1-15-

11 No parallel use of the battery group with different capacities.

12 Each setting parameter shouldnt exceed the regular range of this manual.
13 No over charge or over discharge for normal operation.
14 The temperature shouldnt exceed 40 in the usual use. No hot feeling when
touching the joint point and the terminal.

5.3.2 Capacity detection

1 Equalization charge before capacity detection.
2 The current after switching into float charging is 1~2mA/Ah. If it stays
stable for 2~3hours, it means that the battery is fully charged. Proceed with
capacity detection after power off for 2hours under the condition of 24 hours
float charge. As for the detection standard refer to 5.3-1

Figure5.3-1

capacity detection standard

Discharge

Discharge

Discharge end voltage V/

Capacity detection

rate

currentA

cell

standard

10h

1.0I10

1.80

1.00C10

5h

1.7I10

1.77

0.85C10

3h

2.5I10

1.75

0.75C10

1h

5.2I10

1.67

0.52C10

I10 means discharge current in ten hours, one tenths of the standard capacityC10.
When battery is multi-paralleled, the standard capacity is the sum of each
capacity.
Never discharge the battery till the terminal voltage drops below the above
regulated end voltage.
3 Recharge the battery within 8 hours after discharge.

5.3.3 Discharge
There are three ways to control the discharge depth:
1

Through discharge time, the product of discharge time and load current
should be no more than 0.80C10 Ah
-1-16
-

2 Through discharge capacity to control the discharge depth, the battery capacity
setting should be lower than 0.80C10 Ah
3 Through the discharge end voltage to control discharge depth, that is through
the power off voltage setting to avoid over discharge.

5.3.4 Equalization charge mode

1 Equalization charge the same as the equalization charge in 5.2.1.When
equalization charge current is lower than 20 mA/Ah, the battery turns into float
charge automatically. If the float charge current remains1~2mA/Ah for
2~3hoursit means that the battery is fully charged, then at least 24 hours float
charge is required.
2 Constant current periodically charge with the current of 0..1C10A till the
terminal voltage of the last battery becomes 2.4Vthen charge with the current
of 0.05C10A.

note
The indication of fully charged with constant current: any terminal voltage and
the electrolyte density remains the same for 3hours. of each battery in 3 hours
sessionwith abundant bubble inside of the battery.

3 Constant current first, constant voltage next: charge with the current of
0.1C10Atill the terminal voltage of the last battery is 2.4V then fully charge
the battery with the voltage of 2.4V.

note
The indication of fully charged with constant voltage is the electrolyte density
remains the same for 3hours. of each battery in 3 hours sessionand trhe
current is below 0.01C C10A with abundant bubble inside of the battery.

-1-17-

5.3.5 When to recharge

1. For the battery gone through the charge-discharge cycle, recharge in the means of
5.3.4.2. The charged capacity shouldnt be less than the 120% of the discharged
capacity.
2. During operation, the batteries should be equalizing charged if the float
charge voltage of the single cell is less than 2.18V, and the equalization charge time should be at
least 8 hours but less than 10 hours. If the power supply condition is very poor and there is
frequent power off, then regular charge should be done.
3. If there are some lagging behind batteries, equalization charge should be
done. The lagging behind battery refers to the final discharge voltage of the single cell is less
than 1.8v after discharging 5 hours with the current of 0.10C10A.
4. Equalization charge should be done after emergency discharge or regular capacity
determination. The charge capacity should be no less than 120% of the discharge capacity.
5 equalized charge the battery every under normal usage.
6 Before observation and adjust the electrolyte.

5.3.6 Application Requirements of Power off Time

1. For the circumstances that the battery hasnt been made supplementary charge according to the
requirements after accidental discharge, the batteries cant be used to supply power further if the
power fails again.
2. If the accumulated discharge capacity at a time is 50%- 80% of the rated capacity after power
off, the float charge time should be no less than 24 hours after equalization charge switches to
float charge.
3. If the accumulated discharge capacity is less than 50% of the rated capacity after several times
of power off in one day, the float charge time should be no less than 12 hours after equalization
charge switches to float charge.
4. For the district that there is frequent power failure and each duration time is very long, diesel
generator or auxiliary oil machine is needed. Diesel generator or other auxiliary power devices
should be used to power the equipment in the base station and make supplementary charge to the
batteries just in time if the discharge depth of the batteries is over 80% and main electricity
supply doesnt recover.

-1-18
-

5.3.7 Battery maintenance items figure

The batteries should be checked and maintained regularly to ensure its normal service life. Regularly
maintenance can be classified as three stages, including monthly maintenance, quarterly maintenance and
annual maintenance.
The regular check items are listed in figure5.3-2
items

content

standard

maintenance

ventilation

Open the door and window

No peculiar smell

Ventilate through fan

20

cooling

Period
weekly

temperature
The

electrolyte temperature
should be lower than 40

float

charge

Measure the terminal voltage

voltage of the

of two polarities

float

charge

voltage

multiply

the pieces

battery group
No acid leakage, bulge and

No

damage of the battery container

from

and cover

appearance

dustless

clean

abnormal
the

No

rust

of

the

Check to see no loose of the

parts

bolt and nut

supply

switch

Cut off the AC switch to the

DC

Clean

height
density
Animal

and

the

done if it affects the normal

Remove the rust, change the

rustless

cable

and

coated

with

wring tight the loosened bolt

Connect well
Switch

to

and nut
DC

supply on smooth

With

Clean out the dust

good

ventilation

blot
electrolyte

for

Correct the possible deviation

AC supply

the

acid-proof

reason

antirust

Connection

DC

the

abnormity, alternation must be

cloth

and terminals

monthl

Find

Remove the dust with wet

vertical

installation, connection cable

the standard

operation

The
appearance

Correct the deviation value to

Check after fully charge, refer to

Appendix C

refer to Appendix
C

Get rid of the animal, have the

passage blocked

-1-19-

No animal

Wash with pure water

Refer to Appendix C
Check to see about the dead
angle

items

content

standard

maintenance

ventilation

Open the door and window

No peculiar smell

Ventilate through fan

20

cooling

Period
weekly

temperature

electrolyte temperature
should be lower than 40

The float charge

float charge
voltage
quarterl

of

voltage

Measure the terminal voltage

each battery

temperature

of each battery

compensation

is

50mV
equalization
charge

equalized charge the battery

Equally

half a year

each
The

Discharge with the current of

Discharge
yearly

after

test for the

check

should

the

off

standard value, then turned to

float charge observation
Refer to 5.2

be

larger than 8h at

1.80V/cell, and with the AC cut

charge for those higher than

discharge

time

0.1C10A and the end voltage

charge
battery

Discharge before equalization

end

Equalize charge the battery

of

discharge

5.4 Troubleshooting
Normal troubles analysis & the relative resolutions are listed in . 5.4-1
figure5.3-3 Normal

troubles analysis & the relative resolutions

Trouble

Reason

Resolution

phenomena
At the initial stage of operation,

the voltages of a single battery or

the whole group drop rapidly

when discharging.

The bolts connecting the

Wring the bolts tightly.

terminals are loose.

Clean the terminals and

There is dirt on the surface

connecting

wires

of terminals or connecting

reinstall the bolts.

and

wires which increases the

voltage

drop

at

the

connection part.
The

battery

group

can

be

The protection voltage limit that

Adjust the protection voltage

discharged normally at the initial

stops battery discharge and is

limit, that stops battery discharge

stage of operation, but the load

set

and make a choice according to

will be power off very soon.

management equipment, such as

through

-1-20
-

the

battery

actual situation.

Trouble

Reason

Resolution

phenomena
switch power supply is too high.
The determination value of the

The polarity of a single battery

Correct just in time according to

battery group voltage is 4V lower

in the group is connected

the polarity symbols of the

than the calculated value.

reversely.

battery terminals or the positive

or

negative

symbol

on

the

surface of the battery.

1. The actual total voltage of
the battery group is lower
than the calculated value.

Ground connection of the battery

There exists certain difference

It occurs if there have some

among the voltage values of

minor differences among the

single battery in the same group

inner structures of batteries or

at the initial stage of operation.

produced in transportation and

Disconnect the grounded battery

After normal float charge for 3

months, the voltage values will
tend to be consistent with each
other automatically.

storage.
At the end of operation , some

Difference

difference exist between the voltage

height and density.

between

in the same group

-1-21-

electrolyte

Adjust the electrolyte level and

density

Appendix A Type selection, transportation

and storage
Abstract
This appendix introduces type selection, transportation precautions and
storage requirement.
A.1 Type Selection
The following items should be considered in battery type selection.
1. Operation frequency.
2. Discharge current.
3. Discharge time
4. The capacity of the battery selected should be relatively higher to avoid
some damages to the battery because of over discharge and being
discharged with ultra large current (usually, the discharge current should
be less than 0.1C10A during discharge.)
A.2 Transportation
The handling requirements of the batteries are described below:
1. The M10 screw holes cannot be used directly for the batteries handling.
2. Forbidding rolling, throwing, bumping, and impacting the batteries.
3. Never expose the batteries under the sunshine, rain, or submerge the
batteries into the water.
4. The upper sides and the output terminals of the batteries cannot suffer
direct pressure or pull.
B-1

5. No rust into the battery.

6. Dont short circuit the batteries.
In the battery handling, the following requirements should be met:
1. Handle the battery vertically and carefully.
2. Dont damage the appearances of the batteries.
The manufacturer recommends that slings (inorganic materials) with enough
strength should be used to vertically handle the batteries with the bottom
parts held. Please see Figure A 1-1.

F
th e sta b le rin g o f th e g allu s
g allu s
b attery

-B-2-

figureA.1-1

battery hoisting diagram

A3 Storage
The battery can be stored in the temperature range of 0-35 before
installation. The storage period usually is 3-6 months. Make
supplementary charge to the batteries if storage period is beyond 3-6
months.
The battery should be kept in a dry, clean and ventilated environment
free from large quantities of radiation, organic solvent, corrosive gas, fire
and exposure to sunshine.
Batteries should be stored in vertical position, the coping of battery
cannot suffer pressure, and safety valve cannot be loosened. Batteries
that are not packed in wooden boxes cannot be piled.

-B-3-

Appendix B Technical characteristics

Abstract
The appendix introduces the technical characteristic about the GFX Gel battery
B.1 Discharge characteristics
B.1.1 Discharge characteristic curve
Discharge characteristic curves under different discharge rates, see B.1-1.

D is ch ar g e ch ar a ct er is t ic s 68 F (2 0 C )

No te)

Terminal voltage (V)

2. 1
2. 0
1. 9
0 .1 C 10

1. 8

0 .2 5C 10 0 .1 7C 10
0. 5C 10

1. 7
1. 6
0

4 6 8 10

20

40 6 0

6 8 10

20

40

(M in u te )
(H ou r )
D ur at io n o f di s ch ar ge

Diagram B.1-1 discharge characteristic curves under constant discharge rates

The above is the discharge characteristic diagram which discharge with constant current till the end voltage

20, discharge characteristic curves under constant discharge current of 0.1C10(A)~1.0 C10(A) which
discharge until the end voltage

B.1.2 discharge current and capacity

The discharge current and capacity under different discharge rates, seefigureB.1 2
FigureA.1-2 the discharge current and capacity under different discharge rates,
seefigureB.1 2

Battery type

C10

C5

C3

C1

C0.5

Vt=1.80V/cell

Vt=1.77V/cell

Vt=1.75V/cell

Vt=1.67V/cell

Vt=1.65V/cell

current

capacity

current

capacity

current

capacity

current

capacity

current

capacity

GFX-200

20

200

34.5

172

50

150

106

106

153.9

76.8

GFX-250

25

250

43

215

62.5

187.5

132.5

132.5

192

96

GFX-300

30

300

51.5

258

75

225

159

159

230

115

GFX-350

35

350

60

300

87.5

262.5

185

185

268

134

GFX-420

42

420

72

360

105

315

222

222

322

161

GFX-500

50

500

84

420

122.5

367.5

259

259

375

187

GFX-600

60

600

103

516

150

450

312

312

426

213

GFX-800

80

800

137.5

688

200

600

416

416

568

284

GFX-1000

100

1000

172

860

250

750

520

520

710

355

GFX-1200

120

1200

206.5

1032

300

900

624

624

852

426

GFX-1500

150

1500

252

1260

372

1116

744

744

1056

528

GFX-2000

200

2000

336

1680

496

1488

992

992

1408

704

GFX-2500

250

2500

420

2100

620

1860

1240

1240

1760

880

GFX-3000

300

3000

504

2520

744

2232

1488

1488

2112

1056

GFX-3500

350

3500

588

2940

868

2604

1736

1736

2464

1232

B.1.3 discharge end voltage

The protective voltage settings under different discharge current of Lead acid battery
seeB.1 -3
Discharge current
0.1I10Discharge current

Discharge end voltage

1.9V

0.1I10Discharge currentI10

1.85V

I10Discharge current4I10

1.80V

4I10Discharge current6I10

1.75V

6I10Discharge current10I10

1.70V

A.1 Charge characteristic

The relationship curves between equalization Charge voltage, Current, state of
charge and time under different discharge depths, seeA.1-1
-ii-

(%C 10 Ah)
(I
120

A)

(V)

1 . (20 C )
2. (20 C )

1.2
1

100
80

2
3

0.8

0.4

20 %

2.25
40

2.35

2 50 %

2.15

3 75 %

2.05
0

4 100 %

4
1

10

12

14

16

18

20

22

t(h)

Diagram A.1-2 under different discharge depth, the curve changed with time of the equalization
charge voltagecurrent, capacity

A.2 Life characteristic

The relationship curve between temperature and life of GFX battery
see B.3 -1

Relation curves of service

life and ambienttemperature
1 20
1 00
80
60
40
20

-20

- 10

10

20

30

( )

50

Diagram A.2-1 the relationship curve between temperature and life

-iii-

A.3 Capacity characteristic

A.3.1 The relation between capacity and temperature
See figure B.4 -1

Discharge capacity ( %C )

Discharge capacity Vs
ambient temperature curve (I A)
120
100
80
60
40
-20

-10

10

20

30

40

50 ()

Diagram B.4 -1 The Relationship Curve between discharge capacity and temperature

B.5 The Relationship Curve between Charge Voltage and Environment Temperature See figure B.5 -1
Charge voltage Vs ambient temperature curve
2.60V
2.50V

Balancing charging voltage

2.40V
2.30V
2.20V
Float charging voltage

2.10V

Diagram B.5 -1

-20

-10 0

10

20

30

40

50

relationship curve between charge voltage and environmental temperature(20)

-iv-

Appendix C Confection, perfusion, observation

and adjustment of the electrolyte
Abstract
This appendix introduces about how to confect, perfuse the electrolyte, as well as the
observation and adjustment.

note
Perfusion of the electrolyte is a professional and dangerous job, it is
recommended to purchase the special sulfuric electrolyte(with the density about 1.22
0.0002 g/cm3) from the special manufacturer. And employ the specialist to finish the
work. The introduction is just for reference.

C.1 Perfusion procedure

Preparation
1 Get the acid-proof veil, cloth, glove, boot and the glass ready.
2 Get the following measuring utensils ready: measurement cylinder(500-1000ml
thermometer-10-100
acidity1.200-1.300g/cm31.000-1.200g/cm3electrical
scale 0-100Kg.
3 According to the typequantity and the electrolyte amount in figure2.3-1chapter
2, you can get the needed electrolyte, then convert out the necessary sulfuric and
pure water.
For example: choose the purchased battery GFX-3000 as an example, totally 96
pieces.
The necessary electrolyte for each battery is 63Kg, that is W electrolyte
=63*96=6048 Kg, in volume that is V electrolyte =6048/1.22=4957.4L.
The result about the quantity of the pure water and oil of vitriol, W oil of
vitriol=6048*31%=1874.9
water=4173.1L

-v-

Kg,

water=6048-1874.9

=4173.1Kg

Considering the possible leaked and the standby quantity, you can the result.

note 1
20, the density of the filled electrolyte is 1.22 0.002g/cm3, the quality
percentage is 31%the volume percentage is 21%

note 2
The density of the electrolyte varies with the temperature. Take the density20

as a standardthe equation is t=20-0.00073*(t-20)The temperature is the

measured temperature of the electrolyte. Therefore, special attention should be paid to

the density corresponding to temperature.
4 Get the plastic container which can anti-acid and without deformation under the
hot temperature(V=50L(about) at least 3pieces ), milling bar(200mm longer
than the container), acid-bearing ladle(about 1L), acid-bearing funnel(big caliber
about 150mm, small caliber about18-24mm ), acid absorbing tube
i.

Dish cloth, bucket, mop, envelopabove 10m2

5 1%NaOH solutionused for neutralizing the spilled acid

6 Get additional acid envelop pump if the situation allows air condenses power

A.3.2 Technical requirement for the pure water and vitriol oil
1.

Pure water1McmPH=7neutralcolorless and transparency.

2.

Dense sulfuricH2SO492%Fe0.005%Cl0.0002%transparencymm
160ash0.02%deoxidization of MnSO4 Content0.001%Mn0.00005%
As0.00005%NO0.0002% NH4 0.001% Cu 0.0005% SO2
0.004%greasing colorless and transparence

-vi-

A.3.3 Electrolyte confection

1 Calculate the quantity of the applicable vitriol oil and pure water the electrolyte
density of GFX battery is
1.22 g/cm320
Exampleconfect 30L electrolyte with the 50L container
The added vitriol oil quantity W vitriol oil=30*1.22*31%=11.3 Kg V vitriol oil
=30*21%=6.3 L
The pure water added each time W water=30*1.22-11.3=25.3Kg V
water=25.3L

2Wash all the utensils clean.

3 Protect the electron scale and equipment well, upraise the ambient.
3Wear the overall safety clothes, no skid on the floor.
4 Weigh the necessary acid and pure water.
5 Pure all the water into the container.
6Fill the acid into the container slowly, mill the acid at the same time.

danger
No oil of vitriol into the container before pure water addition.
7 Mill the acid evenly, measure the density after the temperature drops below 40,
convert the density to the standard under 20.
8Compare this density with the confected density at 1.220.002 g/cm3water
addition to dilute and acid addition to dense it until qualification is achieved.

A.3.4 Perfusion
1 Make sure that the density is 1.22 0.002g/cm3converted to 20
With the
below temperature20
2 Wash all the utensils clean.
3 Wear the overall safety clothes, no skid on the floor.
4Cover the floor, battery, battery rack and other equipment with the envelop.
-vii-

5Open all the valves and all the valve ports to plug funnel.

note
If not all the valve ports are open, acid leakage will occur if filling two
quickly.
6 Filling the suitable electrolyte into the battery through the funnel slowly.
7 The level of the filled electrolyte should be equal to or 1cm higher than the
highest level()the battery should be placed erect.
8 Filling the battery according to the requirement, check the battery one by one to
make sure that the level is appropriate.
9 Water the leaked acid first and dry it with dishcloth. NaOH can be used if there
are too much leaked acid, but it must be washed clean.
10Wring the valve on the battery and cover it before install on the rack.
11Initial charge the battery after storing the battery for 8-12 hours when electrolyte
temperature drops below 30.

A.3.5 Observation and adjustment of electrolyte

1 The density should be 1.220.002 g/cm320after electrolyte perfusion but
without initial charge. The level should be equal to the mark of the container.
2The density of the electrolyte after initial charge should be 1.240.002 g/cm325
with the height equal to the mark of the battery cover, otherwise some
adjustment should do to meet it. Add a certain amount of high density acid to the
electrolyte if the density is lower; otherwise replace some electrolyte with some
pure water. After repeated adjustment and a small current charging about 2 hours,
a density at1.240.002 g/cm3 20is qualified. The observation of the
electrolyte level should be done after two hours storage, draw out the electrolyte
that higher than the mark, add the density of 1.240.002 g/cm320if lower
than the mark
3 During the normal operation of the battery, observe the electrolyte level at least
once per week, and measure its density accordingly. Adjustment should be done

-viii-

if the level differs a lot from the container mark. After full charging, electrolyte
density should between.238 g/cm3-1.262 g/cm325.
Usually, the electrolyte level declines during the normal operation, and the density
rises.comparison under the same temperature
As to the battery electrolyte level lower than the container mark and with a
dense density, the first method is very quick but roughly. That is add some water
to rise the level.

note
Only pure water is permitted to add into the battery in the first method.
Second: Increase the electrolyte level according to the method of the second

item, with the density about 1.240.002 g/cm325

note
The premise of the second method is that all the battery are fully charged. And
this method is not for the non-specialist.

-ix-

GFX OPzS
C

-x-

GFX (OPzS)
C

20051212-R1.0
V1.0

225526
http://www. Shuangdeng. com. cn/
05238529806 8529885

4008-899-886

05238912370
E-mailfuste@shuangdeng.com.cn
*

fuste20051111
-xi-

FAX0523-8912370

0523-8912370
225526fuste@shuangdeng.com.cn

GFX (OPzS)C

V1.0

20051212-R1.0

E-mail

FAQ

GFX (OPzS)GFX
(OPzS)

GFX (OPzS)

GFX

A
B

1 ........................................................................................................................................1-1
1.1

1-1

1.2

1-1

2 ................................................................................................................................................2-1
2.1

2-1

2.2

2-1

2.3

2-2

3 ....................................................................................................................................3-1
3.1

3-1

3.2

3-1

4 ................................................................................................................................................4-1
4.1

4-1

4.2

4-1

4.3

4-2

4.4

4-3

4.4.1 ...................................................................................................4-3
4.5

4-7

4.6

4-8

5 ..................................................................................................................5-10
5.1 GFX

5-1

5.1.1 ...........................................................................................5-1
5.1.2 ...........................................................................................................................5-1
5.1.3 ........................................................................................5-2
5-2

5.2

5.2.1 ...............................................................................................................................5-2
5.3

5-4

-i-

5.3.1 ............................................................................................................................... 5-4

5.3.2 ............................................................................................................................... 5-5
5.3.3 ....................................................................................................................................... 5-5
5.3.4 ............................................................................................................................ 5-5
5.3.5 ................................................................................................................... 5-6
5.3.6 ........................................................................................................... 5-6
5.3.7 ................................................................................................... 5-7
5.4

5-17

A ....................................................................................................................... A-1
A.1

A-1

A.2

A-1

A.3

A-1

B ........................................................................................................................................B-1
B.1

B-1

B.1.1 ......................................................................................................................B-1
B.1.2 ..................................................................................................................B-2
B.1.3 ......................................................................................................................B-2
B.2

B-3

B.3

B-3

B.4

B-3

B.4.1 ..................................................................................................B-4
B.5 ....................................................................................................B-5
C .............................................................................................. C-1
C.1 ............................................................................................................................C-1
C.1.1 ...............................................................................................................C-1
C.1.2 ...................................................................................................C-2
C.1.3 .......................................................................................................................C-2
C.1.4 .......................................................................................................................C-3
C.1.5 ...........................................................................................................C-4

-ii-


2.1-1

GFX-200

2-1

2.2-1

GFX-1000

2-1

3.1-1

GFX

3-1

4.4-2

GFX-200/48V

4-4

4.5-1

GFX-200/48V~ GFX-600/48V

4-7

4.5-2

GFX-800/48V~ GFX-1500/48V

4-8

4.5-3

GFX-2000/48V~ GFX-3500/48V

4-8

A.2-1

A-2

B.1-1

B-1

B.2-1

B-3

B.3-1

B-3

B.4-1

B-4

B.5-1

B-4

-i-


1.1-1

1-1

2.3-1

2-2

4.3-1

4-2

4.4-1

4-3

4.5-1

4-7

4.6-1

4-9

5.2-1

5-12

5.2-2

5-12

5.2-3

5-12

5.3-1

5-5

5.3-2

5-16

5.4-1

5-17

B.1-2

B-2

-i-

1.1

1.1-1

1.1-1

1.2

2
3

1-1

5-5

GFX

2.1
GFX (OPzS) GFX
QSXK06-044-00398GFX
2 V GFX-200
2.1-1GFX

GFX-200

Ah

2.1-1 GFX-200

2.2
GFX GFX-1000 2.2-1

2-1

 2.2-1 GFX-1000

2.3
GFX
2.3-1
2.3-1

Ah

kg

mm

mm

mm

mm

GFX-200

200

103

206

354

409

13.5

18.0

4.5

GFX-250

250

124

206

354

409

16.0

21.0

5.0

GFX-300

300

145

206

354

409

19.0

25.0

6.0

GFX-350

350

124

206

470

525

21.5

28.0

6.5

GFX-420

420

145

206

470

525

25.5

33.5

8.0

GFX-500

500

166

206

470

525

29.0

39.0

10.0

GFX-600

600

145

206

645

700

34.0

46.0

12.0

GFX-800

800

191

210

645

700

48.0

64.0

16.0

GFX-1000

1000

233

210

645

700

57.0

77.0

20.0

GFX-1200

1200

275

210

645

700

68.0

92.0

24.0

GFX-1500

1500

275

210

795

850

82.0

112.0

30.0

GFX-2000

2000

399

214

771

826

110.0

150.0

40.0

GFX-2500

2500

487

212

771

826

140.0

190.0

50.0

GFX-3000

3000

576

212

771

826

163.0

225.0

62.0

M10

5-5

GFX

3.1
GFX (+)
3.1-1

0
0
0
3
X
F
G
0
0
5
2
X
F
G

0
0
0
2
X
F
G

GFX800-GFX1500

GFX200-GFX600

3.1-1 GFX

3.2
GFX

PVC

AS
3-1

5-5

GFX

4.1
1 20
2

3 GFX

4.2
1 GFX
GFX
2
3

3
7

4 GFX

5
)

4-1

25Nm
8

10
11

12

4.3
GFX 4.3-1

4.3-1

kg

GFX-200/48V

1640552425

448

GFX-250/48V

1892552425

537

GFX-300/48V

2144552425

622

5-5

kg

GFX-350/48V

1892552515

685

GFX-420/48V

2144552515

798

GFX-500/48V

2396552515

904

GFX-600/48V

2144552600

1118

GFX-800/48V

1544532600

1507

GFX-1000/48V

1544616600

1827

GFX-1200/48V

1544700600

2150

GFX-1500/48V

1544700750

2782

GFX-2000/48V

1578532730

4038

GFX-2500/48V

1566620730

4951

GFX-3000/48V

1566708730

5865

GFX-3500/48V

1566708730

6045

48V

48V

4.4
4.4.1
1

2 4.4-1
GFX-200/48V 4.4-2
4.4-1

(24 )
(GFX-200/48V~GFX-600/48V)

(12 )
(GFX-800/48V~GFX-1500/48V)

(6 )
(GFX-2000/48V~GFX-3500/48V)

()

32

44

23

32

20

23

22

10

23

5-4

 4.4-2 GFX-200/48V

8
9 ()
10
11
12

8
9
10
11 ,
12

5-5

 GFX GFX
GFX A13A23
A13

A14

A15 48V

A16
C 1.5
2
A17
A18
A19

17~19
A20
A21

5-4

A22

A23

GFX B13B25
B13 1.220.002 g/cm3
20 1cm(
C
B14

B15

B16

B17

B18

B19

B20

B21 C
B22

B23 A17-A19

5-5

B24

B25

4.5

4.5-1
4.5-1

GFX-200/48VGFX-600/48V

4.5-1

GFX-800/48VGFX-1500/48V

4.5-2

GFX-2000/48VGFX-3500/48V

4.5-3

4.5-1 GFX-200/48VGFX-600/48V

Pb

Pb

Pb

Pb

Pb

0
0
3
X
F
G

Pb

0
0
3
X
F
G

Pb

0
0
3
X
F
G

Pb

0
0
3
X
F
G

0
0
3
X
F
G

0
0
3
X
F
G

0
0
3
X
F
G

Pb

0
0
3
X
F
G

0
0
3
X
F
G

0
0
3
X
F
G

0
0
3
X
F
G

0
0
3
X
F
G

Pb

)
)

GFX-200/48V

GFX-250/48V

GFX-300/48V

GFX-350/48V

GFX-420/48V

GFX-500/48V

GFX-600/48V

425

425

425

515

515

515

600

1520

1772

2024

1772

2024

2276

2024

4.5-1 GFX-200/48VGFX-600/48V

5-4

2 GFX-800/48VGFX-1500/48V

Pb

0
0
0
1
X
F
G

Pb

0
0
0
1
X
F
G

Pb

0
0
0
1
X
F
G

Pb

0
0
0
1
X
F
G

Pb

0
0
0
1
X
F
G

Pb

0
0
0
1
X
F
G

Pb

0
0
0
1
X
F
G

Pb

0
0
0
1
X
F
G

Pb

0
0
0
1
X
F
G

0
0
0
1
X
F
G

0
0
0
1
X
F
G

0
0
0
1
X
F
G

Pb

Pb

Pb

)
)

)
)

GFX-800/48V

GFX-1000/48V

GFX-1200/48V

GFX-1500/48V

600

600

600

750

462

546

630

630

4.5-2 GFX-800/48VGFX-1500/48V

3 GFX-2000/48V~GFX-3500/48V

Pb

Pb

Pb

Pb

0
0
5
2
X
F
G

Pb

0
0
5
2
X
F
G

0
0
5
2
X
F
G

Pb

0
0
5
2
X
F
G

Pb

0
0
5
2
X
F
G

Pb

0
0
5
2
X
F
G

0
0
5
2
X
F
G

Pb

0
0
5
2
X
F
G

0
0
5
2
X
F
G

Pb

0
0
5
2
X
F
G

0
0
5
2
X
F
G

0
0
5
2
X
F
G

Pb

Pb

GFX-2000/48V

GFX-2500/48V

GFX-3000/48V

GFX-3500/48V

1448

1436

1436

1436

462

550

638

638

4.5-3 GFX-2000/48V~GFX-3500/48V GFX-3000

5-5

4.6
4.6-1
4.6-1

>48V

2.0-2.1V

10

11

12

13

14

15

16

17

18

5-4

GFX

5.1 GFX
5.1.1
1. :a
b 20
2
3
4
5
6 1.5 0.5
7-10-1001.200-1.300g/cm3
8
9 GFX 8 30

5.1.2
1
0.05C10A 66
2
0.1C10A 15 0.05C10A 36
3
0.1C10A 2.4V 0.05C10A
36
5-5

5.1.3
1 1

2 20
3 40 45
50 40

4 3

1
GFX

5.2
5.2.1
1
z

2
5-4

 5.2-1
5.2-1

2.23V/

2.35V/

0.10C10A

0.10C10A

3mV/

3mV/

20
B-5

5.2-2
5.2-2
I10

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

5.2-3
5.2-3

GFX

2.23V/

2.35V/

0.10C10A

57V

45V

3 mV/

35

LVDS

44 V

LVDS

47V

5-5

10h

50mA/Ah

10h

20mA/Ah

50 mV3
20 mV

1 20~30 5.2-1
2 2.35 V/
3 0.1C10 A

5.3
5.3.1
1
2 20

3
4
5
6
7
8
9
10
11
12
5-4

13
14 40

5.3.2
1
2 1~2mA/Ah 2~3
24 2
5.3-1

5.3-1

V/

10h

1.0I10

1.80

1.00C10

5h

1.7I10

1.77

0.85C10

3h

2.5I10

1.75

0.75C10

1h

5.2I10

1.67

0.52C10

I10 10 C10 1/10

3 8

5.3.3
3
1 0.80C10 Ah
2 0.80C10 Ah
3

5.3.4
4 5.2.1 20 mA/Ah
1~2mA/Ah 2~3
24

5-5

5 0.1C10A 2.4V
0.05C10A

6 0.1C10A 2.4V
2.4V

3
0.01C10

5.3.5
1 5.3.4.2
120
2 2.18V
8 10

3 0.10C10 A
5 1.80 V
4 120
5
6

5.3.6
1

5-4

2 50%~80%
24
3 50%
12
4
80%

5.3.7

5.3-2
5.3-2

40

20

50mV

0.1C10A
1.80V/

5-5

8h

5.2

5.4
5.4-1

5.4-1

4V

5-4

GFX

A.1

1
2
3
4
0.1C10

A.2

1 M10
2
3
4
5
6

1
2

A.1-1
B-1

A.2-1

A.3
0~35 3~6
3~6

5-5

GFX

B.1
B.1.1
B.1-1
(20)

U(V)
2.1
2.0
1.9

0.1C 10

1.8

0.25C10 0.17C10
0.5C10

1.7
1.6
0

4 6 8 10

20

40 60

20

40

()

()

B.1-1

4 6 8 10

20 0.1C10A~0.5C10A

B-1

B.1.2
B.1 - 2
B.1-2

C10

C5

C3

C1

C0.5

Vt=1.80V/

Vt=1.77V/

Vt=1.75V/

Vt=1.67V/

Vt=1.65V/

GFX-200

20

200

34.5

172

50

150

106

106

153.9

76.8

GFX-250

25

250

43

215

62.5

187.5

132.5

132.5

192

96

GFX-300

30

300

51.5

258

75

225

159

159

230

115

GFX-350

35

350

60

300

87.5

262.5

185

185

268

134

GFX-420

42

420

72

360

105

315

222

222

322

161

GFX-500

50

500

84

420

122.5

367.5

259

259

375

187

GFX-600

60

600

103

516

150

450

312

312

426

213

GFX-800

80

800

137.5

688

200

600

416

416

568

284

GFX-1000

100

1000

172

860

250

750

520

520

710

355

GFX-1200

120

1200

206.5

1032

300

900

624

624

852

426

GFX-1500

150

1500

252

1260

372

1116

744

744

1056

528

GFX-2000

200

2000

336

1680

496

1488

992

992

1408

704

GFX-2500

250

2500

420

2100

620

1860

1240

1240

1760

880

GFX-3000

300

3000

504

2520

744

2232

1488

1488

2112

1056

GFX-3500

350

3500

588

2940

868

2604

1736

1736

2464

1232

B.1.3
B.1 -3

0.1I10

1.9V

0.1I10I10

1.85V

I104I10

1.80V

4I106I10

1.75V

6I1010I10

1.70V

B-2

B.2

B.2-1

(%C10Ah)
(I A)
120

(V)

(20C )

1.2
1

100
80

2
3

0.8

0.4

20%

2.25
40

2.35

2 50%

2.15

3 75%

2.05
0

4 100%

4
1

B.2-1

10

12

14

16

18

20

22

B.3
GFX B.3 -1

120

(%)

100
80
60
40
20

-20

t(h)

-10
B.3-1

10

20

30

40

5-4

50 ()

B.4
B.4.1
B.4 -1

(%C10)

120
100
80
60
40
-20

-10

B.4 -1

10

20

30

40

50 ()

B.5
B.5 -1

2.60V
2.50V

2.40V
2.30V
2.20V

2.10V

-20

-10 0

B.5 -1

10

20

30

(20)

B-4

40

50

GFX

1.220.002 g/cm3

C.1
C.1.1
1
2 500-1000ml-10-1001.200-1.300g/cm3
1.000-1.200g/cm30-100Kg
3 2.3-1 2

GFX-3000 96
2.3-1 GFX-3000 63Kg W

=63*96=6048 Kg V =6048/1.22=4957.4L
W

=6048*31%=1874.9

Kg V

=4957.4*21%=1041.1 L W =6048-1874.9 =4173.1Kg V =4173.1L

1
20 1.22 0.002g/cm3
31% 21%

5-4

 2
2020
t=20-0.00073*(t-20)

4 V=50L 3
200mm 1L 150mm
18-24mm
5 10m2
6 1%NaOH
7

C.1.2
1.

1McmPH =7

2.

H2SO4 92%0.005%0.0002%
mm1600.02% O 0.001%
Mn0.00005%As0.00005% N
0.0002%NH40.001%Cu0.0005%
SO20.004%

C.1.3
1 GFX
1.22 g/cm320
50L 30L
W

=30*1.22*31%=11.3

Kg V

=30*21%=6.3 L
W =30*1.22-11.3=25.3Kg V =25.3L
2

C-6

3
3
4
5
6

7 40 20
8 1.220.002 g/cm3

C.1.4
2 1.22 0.002g/cm3 20 20
2
3
4
5

6
7 1cm

9 NaOH
5-4


10
11 8-12 30

C.1.5
1 GFX 1.220.002

g/cm320
2 GFX 1.240.002 g/cm325

2 1.24
0.002 g/cm320
2 1.240.002 g/cm320

1.238 g/cm3-1.262 g/cm325

GFX

2
1.240.002 g/cm325

C-8