GasTon®
VALVE REGULATED LEAD-ACID BATTERY
GTS- SERIES
OPERATION MANUAL
GASTON BATTERY INDUSTRIAL LTD.
1999.7
 We really appreciate your wise choice of GTS series Valve-Regulated
Lead-Acid battery. This manual will give you instructions on how to
install, operate and maintain GTS battery, so that the battery can give
a best performance.
 Please carefully read all instructions in this manual before you
proceed with installation. And please keep the manual for reference
during operation.
 It is forbidden to overcharge battery shortly and short circuit shall be
avoided. Please do not attempt to dismantle the battery if some
abnormal phenomena happen. You should contact us immediately and
our technicians will handle the problems or replace the battery in
time.
The manufacturer reserves the right to make alterations without
prior notice concerning the operation manual.
2
Contents
Ⅰ. Brief Introduction--------------------------------------------------1
1. Features -------------------------------------------------------------------1
2. Indication of Type -------------------------------------------------------2
3. Types and Dimensions --------------------------------------------------2
II. Technical Characteristics ----------------------------------------3
1. Capacity and Influence Factor -----------------------------------------3
2. Temperature and Floating Voltage ------------------------------------5
3. Internal resistance and short circuit current--------------------------6
4. Type Selection -----------------------------------------------------------6
III. Installation -----------------------------------------------------------8
1. Installation Mode and Occupied Area of Battery Group ---------- 8
2. Installation Precautions -------------------------------------------------9
3. Installation Procedure ---------------------------------------------------10
Ⅳ. Operation --------------------------------------------------------------22
1. Condition ----------------------------------------------------------------- 22
2. Floating Operation -------------------------------------------------------22
3. Equalized Charge --------------------------------------------------------22
4. Charge ---------------------------------------------------------------------22
5. Storage --------------------------------------------------------------------24
Ⅴ. Maintenance ---------------------------------------------------------25
1. Monthly Maintenance ---------------------------------------------------25
2. Quarter Maintenance ----------------------------------------------------25
3. Yearly Maintenance -----------------------------------------------------25
4. Three-years’ Maintenance ---------------------------------------------25
5. Operation and Maintenance Precautions -----------------------------25
3
4
I. Brief Introduction
1. Features
1.1 Basic Characteristics
1)
Adopts the design of barren-electrolyte and utilizes AGM (microporous glass fiber) separator.
Thus there is a path existing between the positive and the negative. Also non-Sb alloy grid is
chosen to increase vent hydrogen over-potential on the negative plate, which prevent
generation of Hydrogen, finally reaches the goal of no water losing. So during the operation
life, there’s no need to add acid and water, neither to adjust the gravity of the solution.
2)
Reliable seal performance, not emission of acid mist, not erosion to equipment.
3)
Long life and low self-discharge.
4) Compact structure, shock-proof and high energy density design.
1.2 Reliable Seal Technology
1)
Container and lid made of reinforcing ABS plastic. Adopt heat seal technology of ABS
container and lid. The technology conquers epoxy’s weaknesses of aging and brickle. And the
amalgamation of the same ABS material ensures no leakage of solution.
2)
Explosive proof valve with an acid filtering structure. If the pressure inside the battery
exceeds a certain value, the safety valve will automatically open to decrease the pressure.
3)
And it will close till the pressure is normal. The acid filtering structure in the safety valve
prevents emission of acid mist when the safety valve opens.
Excellent resist characteristics of mechanical impact and heat impact, prolong the corruption
distance of sulfuric acid.
1.3 Excellent high rate discharge performance
1)
Unique multiple-segment radial grid
2)
Copper insert pillar, the copper insert’s diameter is as long as 20mm, suitable for high rate
discharge
3) Silver-coated flexible connector, good electric performance and low voltage-decrease.
1.4 Extremely equalized float charge voltage
A unique homogeneous working procedure ensures homogeneous float charge voltage of GTS
batteries.
1
Fig. 1-1 Cell Construction
2. Indication of Type
G
T S — × × × ×
10Hr CAPACITY RATE
STATIONARY
GASTON BATTERY
3. Types and Dimensions
Cell Type
GTS-200
GTS-300
GTS-400
GTS-500
GTS-600
GTS-800
GTS-1000
GTS-1500
Rated Capacity (Ah)
Dimensions(mm)
Rated
Voltage
(V)
C10
C3
C1
Length
Width
Height
2
2
2
2
2
2
2
2
200
300
400
500
600
800
1000
1500
150
225
300
375
450
600
750
1125
110
165
220
275
330
440
550
825
120
161
201
242
283
183
218
305
200
200
200
200
200
244
244
244
366
366
366
366
366
604
604
604
2
Overall
Height
385
385
385
385
385
624
624
624
Weight
(Kg)
16
23
30
38
45
62
76
111
II. Technical Characteristics
1. Capacity and Influence Factor
1.1 Capacity of Battery
The capacity of battery is the capacity that battery can be discharged on the established conditions,
expressed as signal C. The usual unit of capacity is ampere hour, shortened as AH.
The capacity can be expressed in Rated Capacity or Actual Capacity. The Rated Capacity of
GASTON GTS I battery please see Table 1-1. The Actual Capacity is the product of the discharge
current and the discharge time, the unit is AH.
1.2 The Influence Factor of the Actual Capacity
The actual capacity is mainly related with the positive and negative active materials and their
utilization rate. The utilization rate of the materials is mainly influenced with the DOD, the
structure of the battery and manufacture technology. In using process the factors that influence the
actual capacity are discharge rate, discharge modality, end voltage and temperature.
1.2.1
Discharge Rate
The discharge rate is often described as hour-rate and multiple rates.
Figure 2-2 is the discharge characteristics curves at different discharge rates. From the figure we
can see that when we adopt same type battery to discharge, if the discharge rate is higher and the
discharge current is larger, then the discharge time is shorter, and the capacity which can be
discharged is less.
3
Voltage/Cell (V)
2.1
2.0
1.9
1.8
1.7
1.6
0.01 0.02
0.1
0.2
0.5
1
2
5
10
20
50
Discharge Time(h)
Fig. 2-1 Discharge Performance Curves at Different Discharge Rates (25℃)
1.2.2
Temperature
Temperature affects capacity of the battery. Fig. 2-2 is the available capacity curve vs. ambient
temperature. If the ambient temperature is not 25 ℃ , it’s necessary to change the measured
capacity to actual capacity Ce at 25℃according to following formula:
Ce
= CT
/(1 + K (T-25))
T— the ambient temperature
K— temperature modulus, 10hr rate capacity test K=0.006/℃
3hr rate capacity test
K=0.008/℃
1hr rate capacity test
K=0.01/℃
Fig. 2-2 Available Capacity VS. Ambient Temperature
4
Capacity (%)
110
100
90
80
70
60
50
-20
-10
0
10
20
30
40
Ambient Temperature（℃）
1.2.3 End voltage
The end voltage is the lowest working voltage below which the battery can’t be discharged any
more. Usually the 10hr rate end voltage of lead-acid battery is 1.80V, and the 3hr rate and 1hr rate
end voltage are 1.75V.
2. Temperature and Floating Voltage
2.1 Ambient Temperature
The best ambient temperature of using GASTON GTS battery is 25℃. At 25℃, GASTON battery
can be discharged 100% of its capacity. If the ambient temperature is different, it can be improved
with methods as follows:
— Change the environment, such as adopting cooling system, changing the position of the
batteries, and improve ventilation.
— Adopt temperature revising method, if the ambient temperature is higher, decrease the
floating charge voltage; if lower, increase the floating charge voltage.
2.2 Floating Voltage
The purpose of choosing certain floating voltage is to reach the designed life and rated capacity of
5
50
the battery. If the floating voltage is higher, then the floating current is also higher, it will
accelerate the corruption the grid and shorten the life of the battery. If the floating voltage is lower,
the battery can’t be kept in full charged state, this will crystallize PbSO4, decrease the capacity,
and also shorten the life of the battery.
At 25℃, if the floating voltage is 2.23±0.02V/cell, the designed use life of GASTON GTS
battery is 15 years. In other degree, please adjust according to Table 4-2.
3. Internal resistance and short circuit current
The internal resistance of the battery is a dynamic nonlinear parameter that is continuously
changed along with the temperature and discharge state. The internal resistance is the lowest when
battery is full charged. The table 2-1 shows the internal resistance and short circuit current of
GASTON battery in fully charged state according to the DL/T 637-1997 standard of Chinese
Electric Power Department.
Table 2-1. Internal resistance and short circuit current (25℃)
Battery Type
GTS-200
GTS-300
GTS-400
GTS-500
GTS-600
GTS-800
GTS-1000
GTS-1500
Internal resistance (mΩ)
0.514
0.363
0.297
0.218
0.175
0.223
0.189
0.152
Short circuit current (A)
3940
5588
6816
9361
11576
9153
10804
13237
Note: Short circuit current will decrease the voltage of the battery to 0V, and damage the internal
components of the battery.
4. Type Selection
Please select batteries’ capacity according to Fig. 2-3 Selection Curve of Cell Type.
1) First confirm the discharge current and end voltage.
E.g., required constant current output is 125A and the end voltage is1.80V.
2) Confirm the continual working time and ambient temperature.
E.g., the continual working time is 3 hours, and the ambient temperature is 25℃.
3)
Select right battery type according to Fig. 2-3 when the discharge current is 125A and the
discharge time is 3 hours: the minimum capacity is 500Ah.
Fig. 2-3 Selection Curve of Cell Type
6
MONO单体电池(终止电压
CELL BATTERY(end discharge
voltage 1.8v/cell)
T=25℃
1.80V/单体)
T=25℃
放电时间
Discharge
time
分
5min
Discharge current(A)
放
电
电
流
(A)
10min15min
小时
30min40min 60min
2h
3h
5h
10h
3
5
10
15
20
30
(10HR)
200Ah
300
400
500
600
800
1000
1500
50
100
150
200
300
500
1000
1500
2000
3000
2000
3000
200
300
400
500
600
800
1000
1500
2000
3000
7
III.
Installation
1. Installation Mode and Occupied Area of Battery Group
Table 3-1 Installation Mode and Occupied Area of GTS-200 --- GTS-600 Series
Battery Group
Battery
Type
Installation Mode
Horizontal Mode
Floor(s) Voltage
Total
Occupation Area
(V)
Weight L x W x H (mm)
(Kg)
2
24
253
930x344x573
2
48
491
1820x344x573
GTS-200
3
24
245
600x344x833
3
48
491
1210x344x833
4
24
253
460x344x1093
4
48
506
930x344x1093
6
48
491
600x344x1613
2
24
344
1176x344x573
2
48
673
2312x344x573
GTS-300
3
24
336
764x344x833
3
48
673
1538x344x833
4
24
344
583x344x1093
4
48
689
1176x344x1093
6
48
674
764x344x1613
2
24
431
1416x344x573
2
48
851
2792x344x573
GTS-400
3
24
425
924x344x833
3
48
851
1858x344x833
4
24
431
703x344x1093
4
48
862
1416x344x1093
6
48
851
924x344x1613
2
24
531
1662x344x573
2
48
1052
3284x344x573
GTS-500
3
24
526
1088x344x833
3
48
1052
2186x344x833
4
24
531
826x344x1093
4
48
1063
1662x344x1093
6
48
1052
1088x344x1613
2
24
620
1908x344x573
2
48
1229
3776x344x573
GTS-600
3
24
615
1252x344x833
3
48
1229
2514x344x833
4
24
620
949x344x1093
4
48
1240
1908x344x1093
6
48
1229
1252x344x1613
* Total weight and occupation area for reference only.
8
Floor(s)
1
2
2
3
Installation Mode
Vertical Mode
Voltage
Total
Occupation Area
(V)
Weight
LxWxH
(Kg)
(mm)
24
253
1478x336x596
24
245
739x336x1120
48
491
1478x336x1120
48
461
952x336x1650
1
2
2
3
24
24
48
48
424
615
829
796
1478x498x596
739x498x1120
1478x498x1120
952x498x1650
1
2
2
3
24
24
48
48
424
615
829
796
1478x498x596
739x498x1120
1478x498x1120
952x498x1650
1
2
2
3
24
24
48
48
526
516
1032
994
1478x580x596
739x580x1120
1478x580x1120
952x580x1650
1
2
2
3
24
24
48
48
619
607
1213
1168
1478x662x596
739x662x1120
1478x662x1120
952x662x1650
Table 3-2 Installation Mode and Occupied Area of GTS-800 --- GTS-1500 Series
Battery Group
Battery
Type
Installation Mode
Horizontal Mode
Floor(s) Voltage
Total
Occupation Area
(V)
Weight
L x W x H (mm)
(Kg)
2
24
827
1308 x 579 x 661
2
48
1650
2576 x 579 x 661
GTS-800
3
24
827
852 x 579 x 965
3
48
1650
1714 x 579 x 965
4
24
827
694 x 579 x 1269
4
48
1650
1308 x 579 x 1269
6
48
1650
852 x 579 x 1877
2
24
1018
1518 x 579 x 661
2
48
2036
2996 x 579 x 661
GTS-1000
3
24
1018
992 x 579 x 965
3
48
2036
1994 x 579 x 965
4
24
1018
754 x 579 x 1269
4
48
2036
1518 x 579 x 1269
6
48
2036
992 x 579 x 1877
2
24
1420
2040 x 579 x 661
2
48
2840
4040 x 579 x 661
GTS-1500
3
24
1420
1340 x 579 x 965
3
48
2840
2690 x 579 x 965
4
24
1420
1015 x 579 x 1269
4
48
2840
2040 x 579 x 1269
* Total weight and occupation area for reference only.
2. Installation Precautions

The customer can adopt flexible installation methods according to the condition of
installation area. However detailed requirements about installation shall be submitted when
placing the order so that best connection scheme can be determined and installation drawings
can be provided.

GTS-200 --- GTS-600 series batteries can be installed in vertical or horizontal mode,
GTS-800 --- GTS-1500 series batteries must be in installed in horizontal mode.

Please strictly refer to installation drawings when make serial and connection.


Batteries of different capacity and performance can not be connected together.
Batteries must be strictly series-wound or shunt-wound connected according to installation
drawing.
Use insulating instruments during installation.
It is forbidden to place the vertical batteries horizontally without putting foamed plastics
under it.
Do not use large torque to connect batteries.
Installation of abnormal batteries is prohibited.
Batteries are of sealed structure, in normal condition, there’s no danger of cauterization of





9
sulphuric acid. But if batteries are broken in transportation or unloading, wash cauterized
skin and/or eyes with plenty of water immediately, and the person should be sent to hospital
as quickly as possible.

The batteries system should be installed nearer to the load as possible as it can, in orders to
avoid voltage drop of the wire.

After installation, check again the system voltage, the polarity of positive and negative post
to ensure the correct installation.
3. Installation Procedure
3.1 Check battery to assure no damage after unpacking, check accessory against packing list to
assure completeness.
3.2 Installation of battery frame
3.2.1Installation of vertical battery frame
For example, install (48V) system.
a)
As per Fig. 3-1, fix foot-board, two side-boards and one shelf-board with M8 bolts. Finish
installation of first-floor battery frame.
b)
According to Fig. 3-2, fix two side-boards, one shelf-board, first floor side frame, finish
10
installation of second-floor battery frame. Use the same method to fix third floor battery
frame.
c)
According to Fig. 3-3, fix one insulating board, two electric conductive boards with M8 bolts
to form connector of batteries and terminal board of accordant junction.
11
12
d)
According to Fig. 3-4, fix upper-frame and third floor side-board.
Note: Holes should be made previously by the customers if the derivative wires are set upwards.
e)
According to Fig. 3-5, insert baffle-board (it should be done after batteries are already put on
the battery frame). Finish the installation of three layers battery frame.
13
Note: 1) In order to ensure steadiness of the whole battery frame, do not screw bolts tightly during
the process in order to make adjustment, finally screw tightly after adjustment.
2) The customers, who want to install chassis bolts, should first fix the chassis bolts on the ground,
then fix the battery frame with the bolts.
3.2.2Installation of Horizontal Battery Frame
For example, install (48V) system.
a) According to Fig. 3-6, fix two foot slats and iron box with M8 bolts, finish the first floor battery
box.
14
b) According to Fig. 3-7, fix the second iron box with same method, finish installation the second
floor iron box. Use same method to fix up the third, fourth, fifth and sixth iron boxes.
15
c) According to Fig. 3-8, fix connector of batteries and terminal board of accordant junction with
M8 bolts.
16
Fig. 3-8
d) According to Fig. 3-9, put cover-board on the finished battery frame, then finish installation.
Note: (1) In order to ensure steadiness of the whole battery frame, do not screw bolts tightly
during installation in order to make adjustment, finally screw tightly after adjustment.
2) The customers, who want to install chassis bolts, should first fix the chassis bolts on the ground,
then fix the battery frame with the bolts.
17
3.3 Installation of Batteries
(1) Emplace batteries floor by floor or line by line, see Fig. 3-10 or Fig. 3-11. Note to check the
polarity of positive and negative post.
(2) According Fig. 3-10, Fig. 3-11 to connect the line of batteries. The connect mode of connector
see Fig. 3-12, use torque wrench to screw tightly, the torque is 15Nm.
18
19
20
21
IV Operation
1. Condition
The GTS battery can be used in -15℃---+45℃ of the ambient environment. The best ambient
temperature is 25℃.
2. Floating Operation
— GASTON GTS battery can be either floating used or cycle used.
— Floating using is the best operation condition of the battery. The battery is all the while
fully charged in operation, in this condition battery can be used for longest life. During
floating operation, please adjust the charge voltage according to environmental
temperature, see Table 4-1:
Table 4-1 Floating Voltage VS. Ambient Temperature
Environmental Temperature (℃)
0—10
11—15
16—25
26—30
31—35
36—40
Floating Voltage ( V±0.02V/Cell)
2.29
2.26
2.23
2.21
2.20
2.19
3. Equalized Charge
GASTON GTS battery need to be equalized charge on conditions as follows:
— After installation of the battery system, the batteries need to be supplemental charged.
— Floating operation over three months, and the voltage of at least two batteries are lower
than 2.18V.
— Storage over three months.
— Floating operation for three months.
The method of equalized charge is suggested as follows:
— Charge with 2.35V–2.40V/Cell for 24 hours.
Note: Above-mentioned charge time is on condition that temperature changes from 20℃to
30℃.If the ambient temperature decreases, it’s better to increase the charge time; otherwise,
decrease the charge time.
4. Charge
22
After discharge, the batteries should be charged in time. The method is recommended as follows:
— The batteries first should be charged on the constant current of 0.1C10A till the average
voltage of the batteries increases to 2.35–2.40V, then the batteries should be charged with
constant voltage of 2.35–2.40V/Cell, till the charge is finished.
Whether the batteries are fully charged can be decided according to any one of two standards as
follows:
— The charge time is 18–24 hours (the charge time can be shortened when the batteries
weren’t deep discharged, e.g. , the charge time of 20% DOD batteries can be shortened to
10hours.)
— On condition of constant voltage, the value of charge current hasn’t varied for continuous
three hours.
On special condition, the batteries need to be fully charged as soon as possible, then fast charge
should be adopted: the value of limit current should not be longer than 0.25C10A, and the charge
voltage should be 2.35–2.40V per cell.
Fig. 4-1 shows recharge characteristics curve of 100% DOD GTS-500 batteries with 0.1C10A
current and limit voltage 2.35V/Cell (25℃). It can be found the fully discharged batteries can be
charged 100% capacity in 15 hours. Fig. 4-2 shows recharge characteristics curve of 100% DOD
GTS-500 batteries with 0.1C10A current and limit voltage 2.23V/Cell (25℃). It can be found the
fully discharged batteries can be charged 100% capacity in 24 hours.
Fig. 4-1 Recharge Characteristics Curve of 100% DOD GTS-500 Batteries with
0.1C10A Current and Limit Voltage 2.35V/Cell (25℃)
Charging Charging Voltage
Current (A)
70
Capacity
Per Cell (V)
Charged (%)
2.4
Charging Voltage Per Cell
140
60
120
2.3
Capacity Charged
50
100
40
2.2
80
30
60
2.1
20
40
2.0
10
20
Charging Current
0
1.9
0
0
5
10
15
23
Charging Time (h)
20
25
30
Fig. 4-2 Recharge Characteristics Curve of 100% DOD GTS-500 Batteries with
0.1C10A Current and Limit Voltage 2.23V/Cell (25℃)
Charging
Current (A)
70
Charging
Voltage
Per Cell (V)
Capacity
2.3
140
Charged (%)
60
Charging Voltage
Cell
Capacity
Charged
2.2
50
120
Per
100
80
40
2.1
60
30
40
20
2.0
20
10
0
Charging
Current
1.9
0
5
10
15
Charging
Time
20
0
25
30
（h）
5. Storage
All lead acid batteries self-discharge in open circuit. The result is that the voltage of open circuit is
decreased, and the capacity also decreased. During storage please note:
— The self-discharge rate is related with ambient temperature. The self-discharge degree is
smaller when the ambient temperature is lower, otherwise is larger. The requirement
temperature of GASTON GTS batteries’ storage environment is from 0℃ to 35℃. The
storage place must be clean, ventilated and dry.
— An important parameter in storage is open circuit voltage, which is related with density
of the electrolyte. In order to avoid perpetual damage to the plate caused by
self-discharge, the batteries should be supplemental charged if they have been stored for
24
three months. The equalized charge method should be adopted.
— During storage, if the open circuit voltage is lower than 2.10V/Cell, the batteries should
be supplemental charged before use. The equalized charge method should be adopted.
— All batteries, which are ready to store, should be fully charged before storage. It’s
suggested record the storage time in the periodic maintenance record and record the time
when another necessary supplemental charge should be made.
— The quality certificates of GTS batteries record the latest charge time of the batteries, the
next charge time can be calculated according to this charge time.
V Maintenance
In order to assure life, the batteries should be correctly inspected and maintained. The maintenance
methods of GTS batteries is recommended as follows:
1. Monthly Maintenance
Implement the under-mentioned inspection every month:
— Keep the battery-room clean.
— Measure and record the ambient temperature of the battery-room.
— Check each battery’s cleanness, check damage and calorific trace of the terminal,
container and lid.
— Measure and record the total voltage and floating current of the battery system.
2. Quarter Maintenance
— Repeat monthly inspection.
— Measure and record floating voltage of every on-line battery. If more than two cells’
voltage is less than 2.18V after temperature adjustment, the batteries need to be equalized
charged. If the problem is still existed after adopting such measures, the batteries need to
yearly maintenance or even three years’ maintenance. should be processed If all methods
are ineffective, please contact us.
3. Yearly Maintenance
— Repeat quarter maintenance and inspection.
— Check whether connectors are loose or not every year.
— Make a discharge test to check with exact load every year, discharging 30-40% of rated
capacity.
4. Three-years’ Maintenance
— Make a capacity test once every three years and once every year after six years’ operation.
If the capacity of the battery decreases to lower than 80% of rated capacity, the battery
should be replaced.
5. Operation and Maintenance Precautions
— Use insulating instruments in operating and maintaining batteries. Do not lay metal
instruments on batteries.
— Do not use any organic cleanser to clean batteries.
25
— Do not dismantle the safety valves of batteries and add anything into batteries.
— Do not smoke or use fire near batteries.
— Do not use abnormal batteries. (E.g., fast inflation, serious transmogrification and vent
valve detonation.)
— All maintenance works should be done by professionals.
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