lead crystal CNFJ, 3-CNFT, 6-CNFJ, 3-CNFJ, 6-HCNFJ Safety, Storage, Operations And Maitenance Manual

SAFETY, STORAGE, OPERATIONS
AND MAINTENANCE MANUAL

CNFJ / 3-CNFJ / 3-CNFT / 6-CNFJ / 6-HCNFJ / 6-CNFT

P UB LI C AT IO N

|

MAY 2014

2014 BY BETTA BATTERIES. ALL RIGHTS RESERVED.

This document is proprietary to Betta Batteries. This document cannot
be copied or reproduced in whole or in part, without the express written
permission of Betta Batteries.

PLEASE CHECK OUR WEBSITE FOR LITERATURE UPDATES.
WWW.LEADCRYSTALBATTERIES.COM

THIS MANUAL PROVIDES FULL INSTRUC­TIONS REGARDING SAFETY, STORAGE,
OPERATION, AND MAINTENANCE FOR
LEAD CRYSTAL® BATTERIES, AS WELL AS
CERTAIN INSTALLATION CONSIDERATIONS.
FAILURE TO OBSERVE THE PRECAUTIONS
AS PRESENTED MAY RESULT IN DAMAGE
TO EQUIPMENT, INJURY OR LOSS OF LIFE.

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3

GENERAL SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS

Important! Please read this manual. This manual
contains important instructions that should be followed
during storage, installation, operation and maintenance
of Lead Crystal® batteries. It will help to achieve highest
performance of your equipment and extend the lifespan
of your product.

Battery handling and servicing should be performed- or supervised by
personnel who have professional knowledge about batteries and precautionary
measures. Battery replacement by unauthorized personnel is prohibited. When
replacing batteries, please use Lead Crystal® batteries of the same capacity
and size as originals used in equipment.

Do not misuse or mutilate Lead Crystal® Batteries. This could

result in human injury or cause damage to the batteries. In no event will Betta
Batteries be responsible or liable for either indirect or consequential damage or
injury that may result from misuse or mutilation of batteries.

Lead Crystal® Batteries contain sulphuric acid ( < 5%) Sulphuric
acid can be harmful to the skin and eyes. Take precautionary measures

as described in this manual.

It is important to handle batteries correctly when returning
batteries. As the batteries contain lead, any inappropriate
handling of the batteries will have adverse effects on the
environment and on persons. Please check local legislation to obtain

approved handling procedures, or return batteries to authorized service
centers of the manufacturer for replacements.

Do not place batteries in-or near a direct fire.

Do not use an organic solvent to clean batteries.

Batteries may cause electric shock when short circuited.
Always use tools with insulated handles when changing
batteries or while performing maintenance.

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4

SYMBOLS FOR BATTERY USE AND OPERATIONS

PLEASE READ CHAPTER 5 FOR FURTHER DETAILED SAFETY GUIDELINES

READ THE
MANUAL

ELECTRICAL
HAZARD

RECYCLE

Pb

Pb

THIS PRODUCT
HAS PASSED
UL SAFETY
CERTIFICATION

SHORT
CIRCUIT
PREVENTION

DO NOT DISPOSE
BATTERY INTO
TRASH

EYE
PROTECTION

SAFETY
WARNING

NO OPEN
FLAMES
OR SPARKS

THIS PRODUCT
HAS PASSED
CE CERTIFICATION

ADULT
SUPERVISION

THIS PRODUCT
HAS PASSED
IEC/EN 60896-21/22

4

TRANSPORT, STORAGE AND

INSTALLATION

4.1 Battery Transport p27

4.2

Battery Storage p27

4.3

Battery Installation p29

5

OPERATIONS AND

MAINTENANCE

5.1 Float Applications p33

5.2

Battery Life and Temperature p33

5.3

Battery Maintenance p34

5.3.1

Quarterly Maintenance p36

5.3.2

Annual Maintenance p36

6

SAFETY

6.1 General p37

6.2

Safety Equipment and Clothing p37

6.3

Safety Precautions p38

6.3.1 Sulphuric Acid Burns p38

6.3.2

Explosive Gases p39

6.3.3

Electrical Shocks

and Burns p39

7

CUSTOMER SERVICE

TABLE OF
CONTENTS

1

GENERAL INFORMATION

1.1 Introduction p6

1.2

Applications p8

1.3

Product Specification and

Model Identification Method p8

1.4

Product Range p9

1.5

Product Standards p11

1.6

Advantages Summarised p12

2

TECHNICAL SPECIFICATIONS

2.1 Structure characteristics p13

2.1.1 Special Electrolyte

Composition p13

2.1.2

Battery Slot Cover p13

2.1.3

Grid p13

2.1.4

Partition p14

2.1.5

Safety Valve p14

2.1.6

Sealing Performance p14

2.1.7

Positive and Negative

Plates p14

2.1.8

Special Manufacturing

Process p14

2.2

Working Principle p15

3

CHARGE AND DISCHARGE

SPECIFICATIONS

3.1 Charge Characteristics p17

3.1.1

12 Volt Lead Crystal® Batteries p17

3.1.2

6 Volt Lead Crystal® Batteries p19

3.1.3

2 Volt Lead Crystal® Batteries p21

3.1.4 Temperature compensation p23

3.2 Discharge Characteristics p23

3.2.1

Battery Capacity p23

3.2.2

Battery Discharge Rate p24

3.2.3

Influence of Temperature

on Capacity p25

3.2.4

Discharge Voltage p26

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6

GENERAL INFORMATION

INTRODUCTION

Growing demand for batteries on a global scale

Due to the rapid development of the industry, the application of batteries in
transportation, communication, power, military, aviation, marine, commercial
facilities as well as in the daily needs of users has become more extensive.

The performance of conventional lead based batteries is not optimal

Because of its inherent structural characteristics, traditional lead-acid batteries
suffer from plate sulphation, active material loss, high water loss rate,
serious acid pollution, poor low temperature performance, short life cycle,
poor transport safety and other flaws. In order to overcome the structural
weaknesses in lead-acid batteries, gel electrolyte has been used as replacement
in gel batteries. Although it reduces acid mist, reduces water loss rate and
self-discharge rate, and improves the discharge performance, it raises new
problems such as poor penetration of the gel material, weak compatibility
with the AGM separator and a slow reaction to the electrodes.

By its unique technology Lead Crystal® batteries have a high performance

To overcome the fundamental flaws of the lead-acid and gel batteries,
we have successfully developed five exclusive patented technological
innovations in Lead Crystal® batteries. Lead Crystal® batteries are ideal
products to replace lead acid and gel batteries

In line with the industrial development trend of the 21st century, Lead
Crystal® batteries pioneered the new concept of environmentally friendlier
electrolyte and manufacturing, and marked the iconic innovation of
battery technology. The excellent properties of Lead Crystal® batteries is
well received in many provinces and cities in China, and has successfully
entered markets in Southeast Asia, Africa, the Middle East, Europe and

1.1

1

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7

other international markets. They are widely used in solar energy, wind
energy storage systems, telecommunications, UPS power supply, power
stations, railway passenger cars, electric vehicles, electric bikes, beacon
signal indicators and other fields. This new type of environmentally friendly
product is rapidly blending into the consumer lifestyles of many industries
and is widely accepted by institutions and individuals.

The patented technology found in lead crystal batteries uses a special
advanced technology formula, a new type of composite SiO2 electrolyte
developed to completely replace traditional sulphuric acid solution. This in
turn improves the product’s application and safety performance. When the
composite electrolyte reacts with the plates during the charging process,
crystalline electrolyte salts are formed, and the electrolyte is absorbed
into the electrolytic salt. The electrolyte is distributed evenly, in a non­hierarchical manner, and there is no gradient concentration in the upper
and/or lower electrode. The electrical properties of the battery are consistent
and achieve reliable performance. It effectively overcomes the disadvantages
of plate sulphation, active material loss and water loss rate, has good low
temperature and overcharge performance, and greatly improves product life.

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8

Rated capacity in Ah (Amp hours)

Valve controlled, sealed lead crystal storage cell

Energy storage battery

Number of single cells in series 6 = 12 volt, 3 = 6 volt

6 - CN FJ - 120

1.2

1.3

APPLICATIONS

Lead Crystal® batteries can be used in a wide range of applications where
lead acid, Lead Gel batteries or AGM Batteries are used today, including,
but not limited to:

• Telecommunications, Communications Exchange And Transmission Systems;

• UPS Uninterruptible Power Supply, PABX And Microwave Relay Station;

• Radio And Broadcasting Stations;

• Power Plants And Transmission Systems;

• Emergency Lighting Systems;

• Railway Signal, Beacon Signalling System;

• Solar Energy, Wind Energy Storage Systems;

• Hotels, Auditoriums and other Applications.

PRODUCT SPECIFICATION AND MODEL IDENTIFICATION METHOD

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9

PRODUCT RANGE1.4

12 VOLT RANGE

6-CNFJ-7.2

6-HCNFJ-7.2

6-CNFJ-10

6-CNFJ-12

6-CNFJ-14

6-CNFJ-18

6-CNFJ-22

6-CNFJ-24

6-CNFJ-26

6-CNFJ-28

6-CNFJ-35

6-CNFJ-40

6-CNFJ-55

6-CNFJ-65

6-CNFJ-70

6-CNFJ-90

6-CNFJ-100

6-CNFJ-120

6-CNFJ-150

6-CNFJ-180

6-CNFJ-200

6-CNFT-55

6-CNFT-90

6-CNFT-100

6-CNFT-155

6-CNFT-170

0610696122070

0610696122872

0610696122087

0610696122094

0610696122100

0610696122117

0610696122124

0610696122131

0610696122148

0610696122155

0610696122162

0610696122179

0610696122186

0610696122209

0610696122216

0610696122223

0610696122247

0610696122261

0610696122278

0610696122308

0610696122322

0610696122193

0610696122230

0610696122254

0610696122285

0610696122292

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

•

•

•

•

•

7.2

9

10

12

14

18

22

24

26

28

35

40

55

65

70

90

100

120

150

180

200

55

90

110

155

180

2,30

2,57

4,15

4,35

4,55

6,35

6,90

8,50

8,50

9,00

14,50

14,50

18,00

22,00

23,00

28,00

30,00

33,00

45,00

60,00

62,00

18,00

28,00

33,00

48,00

61,00

100

100

100

100

104

170

170

125

125

125

170

172

215

175

215

240

210

234

241

224

224

225

286

228

283

320

151

151

151

151

151

181

181

176

176

176

194

198

229

348

259

306

330

408

486

522

522

277

390

560

559

560

65

65

99

99

99

76

76

166

166

166

132

166

138

167

169

174

172

172

170

240

240

106

108

125

125

125

94

94

94

94

98

170

170

125

125

125

170

172

210

175

210

206

206

211

241

219

219

222

286

228

283

320

ARTICLE
NUMBER

BATTERY
EAN CODE

FRONT
TERMINAL

RATED AH
(10 HOURS)

RATED
VOLTAGE

WEIGHT
(KG)

BATTERY SIZE

L W H TOTAL H

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ARTICLE
NUMBER

BATTERY
EAN CODE

FRONT
TERMINAL

RATED AH
(10 HOURS)

RATED
VOLTAGE

WEIGHT
(KG)

BATTERY SIZE

L W H TOTAL H

6 VOLT RANGE

3-CNFJ-4

3-CNFJ-7,2

3-CNFJ-10

3-CNFJ-12

3-CNFJ-160

3-CNFJ-200

3-CNFT-180

CNFJ-100

CNFJ-200

CNFJ-300

CNFJ-400

CNFJ-500

CNFJ-600

CNFJ-800

CNFJ-1000

CNFJ-1200

CNFJ-1500

CNFJ-2000

CNFJ-2200

CNFJ-3000

0610696122001

0610696122018

0610696122025

0610696122032

0610696122049

0610696122063

0610696122056

0610696122346

0610696122353

0610696122360

0610696122377

0610696122384

0610696122407

0610696122414

0610696122438

0610696122445

0610696122452

0610696122469

0610696122476

0610696122483

6

6

6

6

6

6

6

2

2

2

2

2

2

2

2

2

2

2

2

2

4

7,2

10

12

160

200

180

100

200

300

400

500

600

800

1000

1200

1500

2000

2200

3000

0,77

1,20

2,00

2,10

26,00

30,00

33,00

5,25

15,00

22,00

27,00

32,50

38,50

55,00

64,00

85,00

100,00

120,00

130,00

192,00

70

151

151

151

298

323

306

172

175

176

210

244

301

410

480

401

401

491

491

712

47,5

35

50

50

172

178

168

72

110

154

175

175

175

175

175

351

351

351

351

353

100

94

94

94

227

226

222

205

330

330

330

330

330

330

330

342

342

342

342

341

105

100

100

100

230

230

226

210

335

335

335

335

335

335

335

342

347

347

347

346

2 VOLT RANGE

•

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Table 1.1 Lead Crystal® Batteries Product Range.

IMPORTANT

For the Lead Crystal® batteries Light Traction range,
a separate ‘Safety, Storage, Operations and Maintenance’
manual applies.

PRODUCT STANDARDS

Lead Crystal® batteries are manufactured to meet the following national
and international standards and are manufactured under the ISO 9001,
ISO 14001 and GB/T 24001 system.

• GB/T22473-2008 lead-acid energy storage battery

• GB/T19638.2-2005 fixed type valve-controlled sealed battery

• Q/TDZG05-2010 fixed type valve control sealed lead crystal battery

• BS 6290 part 4, Telcordia SR 4228, Eurobatt guide, UL, IEC-60896-21/22

1.5

LIGHT TRACTION RANGE

0610696122797

0610696122803

0610696122810

0610696122827

0610696122834

0610696122841

0610696122858

0610696122865

6

6

8

8

12

12

12

12

180

210

135

150

70

100

120

150

33,00

35,00

33,00

35,00

26,50

37,00

42,50

50,00

260

260

261

261

269

331

407

484

180

180

181

181

169

176

170

170

270

270

280

295

210

214

239

241

275

275

285

300

215

219

239

241

3-EVFJ-180

3-EVFJ-210

4-EVFJ-135

4-EVFJ-150

6-EVFJ-70

6-EVFJ-100

6-EVFJ-120

6-EVFJ-150

ARTICLE
NUMBER

BATTERY
EAN CODE

FRONT
TERMINAL

RATED AH
(3 HOURS)

RATED
VOLTAGE

WEIGHT
(KG)

BATTERY SIZE

L W H TOTAL H

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ADVANTAGES SUMMARISED

Compared to mainstream rechargeable industrial batteries like lead acid,
lead gel and AGM batteries, Lead Crystal® batteries perform as follows:

• Lead Crystal® batteries can be charged faster

• Lead Crystal® batteries can be discharged deeper (even to 0 Volt!)

• Lead Crystal® batteries have an operating temperature from -40 to

+65 Celsius

• Lead Crystal® batteries can be charged below 0 degrees Celsius

• Lead Crystal® batteries can be cycled more often (1500 @ 80% DOD)

• Lead Crystal® batteries have very low gassing (IEC 60896-21/11)

• Lead Crystal® batteries can be used in a partial state of charge

• Lead Crystal® batteries can be stored for 2 years without top-up charging

• Lead Crystal® batteries hold no cadmium, no antimony and < 5%

sulphuric acid

• Lead Crystal® batteries require no special ventilation or cooling

1.6

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TECHNICAL SPECIFICATIONS

Lead Crystal® batteries are a range of new products that were successfully
developed based on existing batteries. It has better performance characteristics
compared to a conventional batteries and is the result of new technical
breakthroughs. The fundamental issues of serious lead acid battery acid
pollution, electrode sulphation, short life cycle, poor low temperature
performance and other flaws are resolved, setting a high standard of
"efficiency, safety, and long-life".

STRUCTURE CHARACTERISTICS

Special Electrolyte Composition

A unique complex technology is used to synergize a range of inorganic salts
and organic substances, thereby optimizing the reaction between the
electrolyte and the active electrode material, effectively preventing the
active substance to become salt and fall off, and extending its service life.
The electrolyte within the battery crystallizes, leaving no free electrolyte,
no leakage, making the battery safe and reliable. The battery may be installed
using in a variety of orientations, making it easy to use. This opens a wide
range of installation applications, since the risk of electrolyte leakage is
eliminated. This reaction also improves the products safety making it less
harmful to installers and users alike.

Battery Slot Cover

The battery slot cover is made from strong opaque ABS plastic with a
standard V2 flammability rating. It is also available in a V0 and v1 flammability
rating on order.

Grid
The grid is made with high quality corrosion-resistant non-antimony alloy,
to ensure the excellent performance life of the positive grid, improve the
over potential of the anode, and inhibit hydrogen corrosion.

2.1

2.1.3

2.1.2

2.1.1

2