Trojan Manual - Rainbow Power Company
Contents
1. DEEP CYCLE BATTERY TROJAN DEEP CYCLE Trojan makes battery care simple with this guide featuring information on proper testing watering cleaning storage charging equalizing and system configuration Includes a handy glossary for your reference l Building and Maintaining Better Batteries Since 1925 Simple Steps For Longer Battery Life Trojan Battery Company has manufactured batteries for eighty years Our experience shows that the key to achieving optimum performance and long life is a solid battery maintenance program using the simple procedures outlined here Equipment Trojan recommends the following equipment for use in battery care and maintenance e Wrench e Post Cleaner e Distilled Water e Baking Soda e Voltmeter e Petroleum Jelly e Hydrometer e Goggles amp Gloves CAUTION Always wear protective clothing gloves and goggles when handling batteries and electrolyte 0084 Inspection 1 Examine the outside appearance of the battery e Look for cracks in the container e The top of the battery posts and connections should be free of dirt fluids and corrosion If batteries are dirty see Cleaning section e Replace any damaged batteries 2 Any fluids on or around the battery may indicate that electrolyte is spilling leaching or leaking out e Leaking batteries must be replaced 3 Check all battery cables and connections e Look closely for loose or damaged parts e Replace any cable2. the bottom of the fill well 7 Clean replace and tighten all vent caps WARNING Never add acid to a battery Cleaning Check that all vent caps are tight 2 Clean the battery top with a cloth or brush and a solution of baking soda and water e Do not allow any cleaning solution or other foreign matter to get inside the battery 3 Rinse with water and dry with a clean cloth 4 Clean battery terminals and the inside of cable clamps with a post and clamp cleaner 5 Reconnect the clamps to the terminals and thinly coat them with petroleum jelly 6 Keep the area around batteries clean and dry _ Storage Important things to avoid Freezing Avoid locations where freezing temperatures are expected Keeping batteries at a high state of charge also prevents freezing See table next page 2 Heat Avoid direct exposure to heat sources such as radiators or space heaters Temperatures above 80 F accelerate the battery s self discharge characteristics _ Procedure 1 Completely charge the battery before storing 2 Store the battery in a cool dry location protected from the elements 3 During storage monitor the specific gravity flooded batteries or voltage e Stored batteries should be given a boost charge when they show a 70 state of charge or less See table previous page 4 Completely charge the battery before re activating Am w amp g 5 For optimum per
3. 33 12 50 70 1 217 6 19 8 25 12 37 60 1 195 6 12 8 16 12 24 50 1 172 6 05 8 07 12 10 40 1 148 5 98 7 97 11 96 30 1 124 5 91 7 88 11 81 20 1 098 5 83 7 77 11 66 10 1 073 5 75 7 67 11 51 State of charge as related to specific gravity and open circuit voltage Am w g Watering Flooded batteries only Water should only be added after fully charging the battery Prior to charging there should be enough water to cover the plates If the battery has been discharged partially or fully the water level should also be above the plates Important things to remember 1 Do not allow plates to be exposed to air 2 Do not fill the water all the way up to the cap 3 Do not use water with a high mineral content 4 Use only distilled or deionized water CAUTION The electrolyte is a solution of acid and water so skin contact should be avoided Electrolyte 1 8 Below Bottom of Fill Well Max Level discharged a battery dil Procedure 1 Remove the vent caps and check the electrolyte level the minimum level is to the top of the plates 2 If there is no electrolyte visible add just enough water to cover the plates 3 Replace and tighten all water vent caps 4 Put batteries on a complete charge before adding any more water See Charging section 5 Once charging is completed remove the vent caps and check the electrolyte level 6 Add water until the electrolyte level is 1 8 below
4. connect 1 batteries in series parallel Battery System 12 Volt 450 AH Using Four T 105 Deep Cycle Batteries 6 Volts 225AH NOTE These systems can also be configured using 12 volt batteries It is not recommended that you mix batteries of different voltages 9 within the same system 10 11 B X hb gl Battery Terms Explained Active Material In the positive plates the active material is lead dioxide In the negative it s metallic sponge lead When a circuit is created these materials react with sulfuric acid during charging and discharging Ampere Amp A unit of measurement for the electron flow or current through a circuit Ampere Hour Amp Hr AH A unit of measure for a battery s electrical storage capacity calculated by multiplying the current in amperes by the time in hours Example A battery which delivers 5 amps for 20 hours provides 5 amps x 20 hours 100 AH of capacity Capacity Rating The time in minutes that a new fully charged battery will deliver 25 amperes or 75 amperes at 80 F and maintain a terminal voltage equal to or greater than 1 75 volts per cell Cell The basic current producing unit in a battery It consists of a set of positive plates negative plates electrolyte separators and casing A cell s nominal voltage is 2 volts Example A 12 volt battery has 6 cells Circuit The path followed by a flow of electro
5. formance equalize the batteries flooded before putting them back into service See Equalizing section Electrolyte Freezing Point Various States of Charge SPECIFIC STATE OF FREEZING GRAVITY CHARGE TEMPERATURE 1 280 100 92 0 F 1 265 92 71 3 F 1 250 85 62 0 F 1 200 62 16 0 F 1 150 40 5 0 F 1 100 20 19 0 F Source BCI Battery Service Manual 1995 Charging Correctly charging batteries requires administering the right amount of current at the right voltage Most charging equipment automatically regulates these values Some chargers allow the user to set these values For proper charging refer to the instructions that came with your charging equipment Important things to remember 1 Become familiar with and follow the instructions from the charger manufacturer 2 Batteries should be charged after each period of use 3 Lead acid batteries do not develop a memory and need not be fully discharged before recharging 4 Charge only in well ventilated areas Keep sparks or flames away from a charging battery 5 Verify charger voltage settings are correct 6 Check electrolyte level See Watering section 7 Tighten all vent caps before charging 8 Do not overcharge or undercharge the batteries 9 Never charge a frozen battery 10 Avoid charging at temperatures above 120 F aa A SS wee mht Equalizing Flooded batteries only WARNING Do not equalize Gel or AGM batteries Equali
6. ns A closed or short circuit is a complete path An open circuit has a broken path Cycle One discharge of a battery plus one recharge Depth of Discharge DOD The percentage of capacity actually removed from a battery compared to the total rated capacity Electrolyte In a deep cycle battery it is a dilute solution of sulfuric acid and water Hydrometer A tool used to measure the specific gravity of the electrolyte solution Equalization An overcharge performed on flooded lead acid batteries after they have been fully charged This maintenance step helps eliminate stratification and sulfation 12 Ohm Q A unit of measurement for electrical Notes resistance within a circuit 13 Open Circuit Voltage The voltage of a battery when there is no load attached not receiving or delivering energy This measurement is best taken when the battery has been at rest for at least 6 hours 14 Power Inverter An electronic device that converts direct current DC power from a battery into standard alternating current AC house power 15 Primary Battery An energy storage device that can deliver energy but cannot be recharged i e disposable flashlight battery 16 Secondary Battery An energy storage device than can deliver energy and can be recharged i e automotive or deep cycle battery 17 Separator A divider made of porous material that is placed between the positive and negative
7. plates in a battery cell and allows current to flow through it while preventing direct contact between the plates which would cause a short circuit 18 Specific Gravity S G A measurement of the strength of battery electrolyte by comparing its density to that of pure water 19 Stratification A condition where the concentration of acid is greater at the bottom of the battery than at the top 20 Sulfation The formation of lead sulfate on the positive and negative electrodes 21 Volt V A unit of measurement for electrical potential within a circuit 22 Watt W A unit of measurement for electrical power 23 Watt Hour Wh A unit of measurement for electrical power for a certain period of time Suggested Maximum Ampacity for Copper Wire WIRE GAUGE SIZE AMPACITY AWG AMPERES 14 25 12 30 10 40 8 55 6 75 4 95 2 130 1 150 1 0 170 2 0 265 4 0 360 Ampacity is the ultimate safe current carrying capacity of the wire before damage occurs to the insulation These are suggested ampacities Refer to the National Electric Code or your local code for correct wire size usage Fore more information please visit www trojanbattery com or call 800 423 6569 and speak to our Applications Engineers Trojan BATTERY COMPANY Available from Master Distributors Worldwide 562 946 8381 800 423 6569 Fax 562 236 3282 www trojanbattery com i Trojan Clean energy for life DCMF 3 05
8. s again If any specific gravity reading still registers low follow these steps 1 Check voltage level s 2 Perform equalization charge See Equalizing 3 Take specific gravity readings again aa A SS wee tt A If any specific gravity reading still registers lower than the factory specification one or more of these conditions may exist 1 The battery is old and nearing end of life 2 The battery was left discharged too long 3 Electrolyte was lost due to spillage 4 A weak or bad cell is developing 5 The battery was over watered prior to testing Batteries in conditions 1 4 should be taken to a specialist for further evaluation or retired from service Open Circuit Voltage Testing For accurate voltage readings batteries must remain idle no charging no discharging for at least 6 hours and preferably 24 hours 1 Disconnect all loads from the batteries 2 Measure the voltage with a DC voltmeter 3 Check the state of charge with the table below 4 Charge the battery if it registers 0 70 charged If battery registers below table values these conditions may exist 1 The battery was left discharged too long 2 The battery has a bad cell Batteries in these conditions should be taken to a specialist for further evaluation or retired from service STATE SPECIFIC GRAVITY OPEN CIRCUIT VOLTAGE OF CHARGE CORRECTED TO 80 F 6VOLT 8VOLT 12 VOLT 100 1 277 6 37 8 49 12 73 90 1 258 6 31 8 41 12 62 80 1 238 6 25 8
9. that is broken or frayed WARNING Do not smoke near batteries 4 Tighten all wiring connections to the proper specification following page Be sure there is good contact with the terminals WARNING Do not over tighten terminals Over tightening can result in post breakage post meltdown or fire Am kL g Proper Torque Values for Connection Hardware Flooded Automotive 50 70 in lbs Side 70 90 in lbs Wingnut 95 105 in lbs LPT 95 105 in lbs LT 100 120 in lbs Gel Button 90 110 in lbs LT 100 120 in lbs Specific Gravity Testing Flooded batteries only 1 Do not add water prior to testing 2 Fill and drain the hydrometer 2 4 times before drawing a sample from the battery 3 Have enough sample electrolyte in the hydrometer to completely support the float 4 Take a reading record it and return the electrolyte to the cell 5 Check all cells in the battery repeating the steps above 6 Replace vent caps and wipe off any electrolyte that might have been spilled 7 Correct the readings to 80 F e Add 004 to readings for every 10 above 80 F e Subtract 004 for every 10 below 80 F 8 Check the state of charge using the table on the next page The readings should be within the factory specification of 1 277 007 If any specific gravity reading registers low follow these steps 1 Check and record voltage level s 2 Put batteries on a complete charge 3 Take specific gravity reading
10. zing is an overcharge performed on flooded lead acid batteries after they have been fully charged It helps eliminate stratification and sulfation two conditions that can reduce the overall performance of a battery Trojan recommends equalizing only when low or wide ranging specific gravity 015 is detected after fully charging a battery Procedure Verify that batteries are the flooded type Remove all loads from the batteries Connect battery charger Set charger to equalizing mode Start charging batteries Batteries will begin gassing and bubbling vigorously Take specific gravity readings every hour Equalization is complete when specific gravity values no longer rise during the gassing stage OoahWoND CON NOTE Many chargers do not have an equalization setting so this procedure cannot be used Am x How To Increase System Power Two or more batteries can be easily connected to boost your system s voltage and or capacity There are three methods to obtain additional voltage and or capacity as described below To increase voltage connect batteries in series Battery System 12 Volt 225 AH Using Two T 105 Deep Cycle Batteries 6 Volts 225 AH To increase amp hour capacity connect batteries in parallel Battery System 6 Volt 450 AH Using Two T 105 Deep Cycle Batteries 6 Volts 225 AH To increase both voltage and amp hour capacity
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