TROJAN BATTERY USER'S GUIDE
Contents
1. E Trojan BATTERY COMPANY TROJAN BATTERY USER S GUIDE Congratulations on your purchase from Trojan Battery Company the manufacturer of the world s most trusted deep cycle batteries The battery you purchased was engineered by Trojan to deliver superior power performance durability and reliability for use in a broad range of demanding applications TROJAN BATTERY USER S GUIDE Table of Contents 1 Equipment Needed 4 2 Battery 4 2 1 E E E EEEE E een Ea 4 2 2 Battery Connections 252 2 4 4 EE 5 Cable SIZ6 i 225 5 2 2 2 TORQUE 5 Romeo oc 6 2 2 3 Terminal 6 2 3 Ventilation Pee ake see eee ee 6 2 4 Connecting Batteries to Increase System 7 2 4 1 Series Connections eda 7 2 4 2 Parallel 7 2 4 3 Series Parallel Connections 8 2 5 Battery Orientation agatha Ada ost ageing2. 14 TROJAN BATTERY USER S GUIDE Table 4 gt f Charge as a measure of S ity and Open Circuit Voltage Percentage Specific Open Circuit Voltage Charge Gravity Cell 6 Volt 12 Volt 100 1 277 2 122 6 37 12 73 90 1 258 2 103 6 31 12 62 80 1 238 2 083 6 25 12 50 70 1 217 2 062 6 19 12 37 60 1 195 2 04 6 12 12 24 50 1 172 2 017 6 05 12 10 40 1 148 1 993 5 98 11 96 30 1 124 1 969 5 91 11 81 20 1 098 1 943 5 83 11 66 10 1 073 1 918 5 75 11 51 4 1 Storage in Hot Environments greater than 90 F 32 C Avoid direct exposure to heat sources if possible during storage Batteries self discharge faster in high temperatures If batteries are stored during hot summer months monitor the specific gravity or voltage more frequently approximately every 2 4 weeks 4 2 Storage in Cold Environments less than 32 F or 0 C Avoid locations where freezing temperatures are expected if possible during storage Batteries can freeze in cold temperatures if they are not fully charged If batteries are stored during cold winter months it is critical that they are kept fully charged 5 How To Maximize the Performance of Your Trojan Battery e Follow all the procedures in this User s Guide for proper installation maintenance and storage e Do not discharge your battery more than 80 This safety factor will eliminate the chance of over discharging and damaging your battery e If you
3. 8 3 Preventative 9 3 1 INSPOCHON ies icc Geka ee ee eel eee eRe 9 3 2 whic nd Pea nase a ye Eee eee 9 3 3 Watering flooded wet batteries 10 11 3 4 Charging and 0 4 1 12 3 4 1 CHARGING ss essed ev creatine anh eden a een 12 13 3 4 2 Equalizing flooded wet batteries 14 4 Storage 14 15 41 Storage in Hot Environments greater than 90 F or 32 C 16 4 2 Storage in Cold Environments less than 32 F or 096 16 5 How To Maximize the Performance of Your Trojan Battery 16 6 What to Expect from Your Trojan Battery 16 7 Trouble Shooting 17 Preparation for Testing ss rea soie anh anda alae ded 17 1 0 On Charge Voltage 0 17 7 3 Specific Gravity Testing 025 64 18 7 4 Open Circuit Voltage Testing 18 7 5 Discharge Testing elses eek 19 8 Battery Recycling 0
4. TROJAN BATTERY USER S GUIDE Trojan Battery Company would like to thank you for selecting our battery With over 80 years of experience Trojan Battery is the world s most trusted name in deep cycle battery technology backed by our outstanding technical support We look forward to serving your battery needs 2008 Trojan Battery Company All rights reserved Trojan Battery Company 12380 Clark St Santa Fe Springs CA 90670 USA This publication is protected by copyright and all rights are reserved No part of it may be reproduced or transmitted by any means or in any form without prior consent in writing from Trojan Battery Company Trojan Battery Company is not liable for direct indirect special exemplary incidental or consequential damages that may result from any information provided in or omitted from this manual under any circumstances Trojan Battery Company reserves the right to make adjustments to this manual at any time without notices or obligation Trojan Battery Company and the Trojan Battery logo are registered trademarks of Trojan Battery Company Plus Series is a trademark of Trojan Battery Company in the United States and other countries Notes 80 S0 jan
5. Mr 1 0 009 T 27 where Mc is the corrected minutes Mr is the minutes recorded and T is the temperature at the end of discharge in C If the discharge time is greater than 50 of the batteries rated capacity then all the batteries are operational Reconnect the discharger to record the individual battery voltage while still under load current being drawn If the discharge runtime is less than 50 of the batteries rated capacity the batteries with a voltage that is 0 5V lower than the highest voltage may be a failed battery There are other methods of testing batteries including internal resistance i e CCA testers and carbon pile discharge testers However these are not suitable testing methods for deep cycle batteries 19 TROJAN BATTERY USER S GUIDE 8 Battery Recycling Lead acid batteries are the environmental success story of our time because more than 97 percent of all battery lead is recycled In fact lead acid batteries top the list of the most highly recycled consumer products and Trojan Battery supports proper recycling of your battery to keep the environment clean Please contact your nearest Trojan Distributor which can be located at www trojanbattery com to properly recycle your batteries Below is the process in which your Trojan battery will be recycled Transportation The same network that distributes new batteries also safely collects and returns used batteries for recycling At the
6. Torque in Ibs AP 50 70 100 120 LPT HPT WNT DWNT UT 95 105 ST 120 180 For DT Automotive Post amp Stud refer to AP or ST type WARNING Use a wrench with a rubber handle when making battery connections 2 3 2 2 3 Terminal Protection Corrosion can build up on terminals if they are not kept clean and dry To prevent corrosion apply a thin coat of petroleum jelly or terminal protector that can be purchased through your local battery dealer Ventilation Flooded wet lead acid batteries release small amounts of gas during usage particularly during the charging process Gel and AGM batteries generally do not release gas but can if too much pressure builds up during charging It is critical to charge batteries in a properly ventilated area For more assistance in calculating ventilation needs please contact Trojan Battery Company s technical support engineers at 800 423 6569 or 1 562 236 3000 TROJAN BATTERY USER S GUIDE 2 4 Connecting Batteries to Increase System Power 2 4 1 2 4 2 Series Connections To increase voltage connect batteries in series This will not increase the system capacity Refer to Diagram 1 for series connections Diagram 1 Example Two T 105 6V Batteries rated at 225AH Connected in Series System Voltage 6V 6V 12V System Capacity 225AH Parallel Connections To increase capacity connect batteries in parallel This will not increas
7. have any questions or concerns about battery care please contact Trojan Battery Company s technical support engineers at 800 423 6569 or 1 562 236 3000 before a problem develops 6 What to Expect from Your Trojan Battery e Anew battery will not deliver its full rated capacity This is normal and should be expected as it takes time to work the battery up e Trojan s batteries take between 50 100 cycles to work up to providing full peak capacity e When operating batteries at temperatures below 80 F 27 C they will deliver less than the rated capacity For example at 0 F 18 C the battery will deliver 50 of its capacity and at 80 F 27 C it will deliver 100 of its capacity e When operating batteries at temperatures above 80 F 27 C they will deliver more than the rated capacity but the battery life will be reduced e The life of a battery is difficult to predict as it will vary with application frequency of usage and level of maintenance 16 TROJAN BATTERY USER S GUIDE 7 Trouble Shooting 17 These battery testing procedures are guidelines only for identifying a battery that may need to be replaced Unique situations may be observed that are not identified within this procedure Please contact Trojan Battery Company s technical support engineers at 800 423 6569 or 1 562 236 3000 for help interpreting the test data 7 1 Preparation for Testing 7 2 Check that all vent caps are secured properly on
8. recycling facility used batteries are broken apart and separated into components to begin the recycling process Plastic Plastic pellets recycled from battery cases and covers are used to manufacture new cases and covers Ze yi 154 Plastic pellets New Covers and Cases New battery covers and cases are manufactured using recycled plastic pellets New cases and 4 Graphics provided by Battery Council International oy 62 Lead Lead ingots recycled from battery grids other battery parts e g posts and terminals and lead oxide are used to manufacture lead for new grids parts and lead oxide Melt grids Lead ingots Qe New Grids and Lead Oxide New battery grids are manufactured from recycled lead Recovered lead oxide is also used in new battery manufacturing id Lead Oxide Electrolyte Option 1 Sodium sulfate crystals separated from used electrolyte dilute sulfuric acid is recycled and sold for use in textiles glass and detergent manufacturing Neutralize electrolyte New Battery Electrolyte Option 2 At some recyclers used electrolyte is reclaimed and reused in manufacturing new batteries At others it is neutralized and managed according to federal and state water permits 5 Electrolyte Electrolyte is neutralized is chemically sentto treated and a water reused treatment plant 20
9. 20 0004 crate eee bee eae nes weed Eee ee 20 TROJAN BATTERY USER S GUIDE This User s Guide was created by Trojan s applications engineers and contains vital information regarding proper care and maintenance of your new battery Please read through this user s guide carefully and completely before using your battery It will help you achieve optimum performance and long life from your new investment 1 Equipment Needed Goggles and gloves Distilled or treated water i e de ionized reverse osmosis etc Rubber handled wrench Baking soda Post protector i e petroleum jelly anti corrosion spray etc Voltmeter for flooded wet gel and AGM batteries Hydrometer for flooded wet batteries Discharge tester if available Battery charger 2 Battery Installation To ensure you install your batteries properly and safely please use the following guidelines 2 1 Safety Always wear protective clothing gloves and goggles when handling batteries Do not smoke near batteries Keep sparks flames and metal objects away from batteries Use a wrench with a rubber handle when making battery connections The electrolyte is a solution of acid and water so avoid skin contact If acid contacts your skin or eyes flush with water immediately Check that all cable connections to the terminal are properly tightened connections that are too tight or too loose could result in post breakage meltdown or fire To avoid short circuits do not
10. Violent self discharge lower on charge voltage Selenium 2 0 Positive shedding Zinc 4 0 Slight self discharge at negative 11 3 4 Charging and Equalizing 3 4 1 Charging Proper charging is imperative to maximize battery performance Both under or over charging batteries can significantly reduce the life of the battery For proper charging refer to the instructions that came with your equipment Most chargers are automatic and pre programmed Some chargers allow the user to set the voltage and current values Refer to Diagram 4 for Trojan s recommended flooded wet charging guidelines Diagram 5 for Trojan s recommended gel charging guidelines and Diagram 6 for Trojan s recommended AGM charging guidelines e Make sure the charger is set to the appropriate program for flooded wet gel or AGM depending on the type of battery you are charging e Batteries should be fully charged after each use e Lead acid batteries flooded wet gel AGM do not a memory effect and therefore do not need to be fully discharged before recharging e Charge only in well ventilated areas Check electrolyte level to make sure plates are covered with water before charging flooded wet batteries only Check that all vent caps are secured properly on the battery before charging Flooded wet batteries will gas bubble towards the end of charge to ensure the electrolyte is properly mixed e Never charge
11. a frozen battery e Avoid charging at temperatures above 120 F 49 C Diagram 4 Recommended Flooded Wet Charging Profile Voltage Current per cell Charge Current Amps 2 45 10270 lt 10 13 Cy 25 C 77 OF 2 35 5 Total Charge Input is 107 to 120 of Amp Hours of Capacity Charge Voltage Removed 1 3 Coy 20 90 100 State of Charge Note Charging time will vary depending on battery size charger output and depth of discharge 12 TROJAN BATTERY USER S GUIDE Diagram 5 Recommended Trojan Deep Cycle Gel Charging Profile Voltage Current per cell Charge Current Amps gree eae E 5 2 35V to 2 40V EEEN Total Charge Input is 25 C 77 105 to 109 of Amp Hours of Capacity Charge Voltage Removed _ Approximately 200 Will increase with age 20 80 100 State of Charge Note Charging time will vary depending on battery size charger output and depth of discharge Diagram 6 Recommended Trojan AGM Charging Profile Voltage Current per cell Charge Current Amps se ees 5 2 35 to 2 450 25 C 77 F Charge Voltage __ Approximately C 200 Will increase with age 20 80 100 State of Charge Note Charging ti
12. connections Replace any damaged cables Tighten any loose connections Refer to Torque Values section 2 2 2 Cleaning Check that all vent caps are secured properly on the battery Clean the top of the battery terminals and connections with a cloth or brush and a solution of baking soda and water Do not allow cleaning solution to get inside the battery Rinse with water and dry with a clean cloth Apply a thin coat of petroleum jelly or terminal protector that can be purchased through your local battery dealer Keep the area around batteries clean and dry 3 3 Watering flooded wet batteries ONLY Water should never be added to gel or AGM batteries as they do not lose water during use Flooded wet batteries need to be watered periodically The frequency depends upon battery usage and operating temperatures Check new batteries every few weeks to determine the watering frequency for your application It is normal for batteries to need more watering as they age e Fully charge the batteries prior to adding water Only add water to discharged or partially charged batteries if the plates are exposed In this case add just enough water to cover the plates and then charge the batteries and continue with the watering procedure below e Remove the vent caps and place them upside down so that dirt does not get on the underside of the cap or for Plus Series batteries simply flip open the cap Check the electrolyte level e Ifthe electrolyte le
13. e the system voltage Refer to Diagram 2 for parallel connections Diagram 2 Example Two T 105 6V Batteries rated at 225AH Connected in Parallel System Voltage 6V System Capacity 225AH 225AH 450AH 2 4 3 Series Parallel Connections To increase both voltage and capacity connect additional batteries in series and parallel Refer to Diagram 3 for series parallel connections Diagram 3 Example Four T 105 6V Batteries rated at 225AH Connected in Series Parallel System Voltage 6V 6V 12V System Capacity 225AH 225AH 450AH 2 5 Battery Orientation Flooded wet batteries must be placed upright at all times Fluid in the battery will spill if the battery is placed on its side or at an angle Gel or AGM batteries are spill proof so they can be placed either upright or on its side TROJAN BATTERY USER S GUIDE 3 Preventative Maintenance 3 1 3 2 Inspection Examine the outside appearance of the battery The tops of the batteries and terminal connections should be clean free of dirt and corrosion and dry Refer to Cleaning section 3 2 If fluids are on the top of a flooded wet battery this may mean that the battery is being over watered Refer to Watering section 3 3 for proper watering procedure If fluid is on the top of a gel or AGM battery this means that the battery is being overcharged and the performance and life will be reduced Check battery cables and
14. lay objects on top of battery e Charge batteries in a well ventilated area e Never add acid to a battery TROJAN BATTERY USER S GUIDE 2 2 Battery Connections Battery cables provide the link between the batteries equipment and charging system Faulty connections can lead to poor performance and terminal damage meltdown or fire To ensure proper connections please use the following guidelines for cable size torque values and terminal protection 2 21 Cable Size Battery cables should be sized to handle the expected load Refer to Table 7 for the maximum current carrying capacity amps based on the cable wire gauge size Table 1 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 Table values are for cable lengths less than 6 feet 1829 mm In series parallel battery banks it is preferable for all series cables to be the same length and all parallel cables to be the same length For more information refer to the National Electric Code for correct cable wire size which can be located at www nfpa org 2 2 2 Torque Values Tighten all cable connections to the proper specification to make sure there is good contact with the terminals Over tightening the connection to the terminal can result in terminal breakage and loose connections which can result in meltdown or fire Refer to Table 2 for the proper torque values based on the type of terminal on your battery Table 2 Terminal Type
15. me will vary depending on battery size charger output and depth of discharge 13 3 4 2 Equalizing flooded wet batteries ONLY Equalizing is an overcharge performed on flooded wet batteries after they have been fully charged Trojan recommends equalizing only when batteries have low specific gravity below 1 250 or wide ranging specific gravity 0 030 after fully charging a battery Gel or AGM batteries should never be equalized e Confirm that the batteries flooded wet e Check electrolyte level to make sure plates are covered with water before charging Check that all vent caps are secured properly on the battery before charging Set charger to equalizing mode The batteries will gas bubble during the equalization process Measure the specific gravity every hour Discontinue the equalization charge when the gravity no longer rises WARNING Do not equalize gel or AGM batteries 4 Storage Charge battery before placing in storage Store in a cool dry location protected from the elements Disconnect from equipment to eliminate potential parasitic loads that may discharge the battery Batteries gradually self discharge during storage Monitor the specific gravity or voltage every 4 6 weeks Stored batteries should be given a boost charge when they are at 70 state of charge SOC or less Refer to Table 4 for specific gravity and voltage measurements When batteries are taken out of storage recharge before use
16. the battery Clean the top of the battery terminals and connections with a cloth or brush and a solution of baking soda and water Do not allow cleaning solution to get inside the battery Rinse with water and dry with a clean cloth Check battery cables and connections Replace any damaged cables Tighten any loose connections Refer to Torque Values section 2 2 2 For flooded wet batteries check the electrolyte level and add water if necessary Refer to Watering section 3 3 Fully charge batteries On Charge Voltage Testing Disconnect and reconnect DC plug to restart charger While the batteries on charge record the current the last 7 hour of charge if possible and measure the battery set voltage If the current at the end of charge is below 5 amps and the battery set voltage is above 56V for a 48V system 42V for a 36V system 28V for a 24V system 14V for a 12V battery 9 3V for a 8V battery or 7V for a 6V battery then proceed to the next step Otherwise check the charger for proper output and recharge the batteries if necessary If the set voltages are still low you may have a failed battery While the batteries are on charge measure the individual battery voltages If any battery voltage is below 7V for 6V battery 9 3V for 8V battery and 14V for 12V battery and a voltage variation is greater than 0 5V for 6V battery 1 0V for a 12V battery from any other battery in set it may be a failed battery Specific Gravity Tes
17. ting flooded wet batteries ONLY 7 3 7 4 Fill and drain the hydrometer 2 3 times before drawing a sample from the battery Measure specific gravity readings for all battery cells Correct specific gravity readings for temperature by adding 0 004 for every 10 F 5 C above 80 F 27 C and subtract 0 004 for every 10 F 5 C below 80 F 27 C If every cell in the battery set is below 1 250 the batteries may be undercharged recharge batteries If any battery has a specific gravity variation of more than 0 050 between cells equalize the set If there is still a variation there may be a failed battery Open Circuit Voltage Testing This is the least preferred method of evaluating the performance of a battery For accurate voltage readings batteries must remain idle at least 6 hours but preferably up to 24 hours Measure the individual battery voltages If any battery voltage is greater than 0 3V from any other battery in set equalize the set flooded wet batteries ONLY Refer to equalizing section 3 4 2 Remeasure the individual battery voltages If any battery voltage is still greater than 0 3V from any other battery in set you may have a failed battery 18 TROJAN BATTERY USER S GUIDE 7 5 Discharge Testing Connect and start discharger Record the runtime minutes when discharge is complete Correct runtime minutes for temperature using the following formula valid between 24 C 75 F and 32 C 90 F Mc
18. vel is well above the plates then it is not necessary to add more water e If the electrolyte level is barely covering the plates add distilled or de ionized water to a level 1 8 3 mm below the vent well this is the plastic shield inside the vent hole for standard batteries and to the maximum MAX level indicator for Plus Series batteries e After adding water secure vent caps back on batteries e Tap water may be used if the levels of impurities are within acceptable limits Refer to Table 3 for Water Impurity Limits TROJAN BATTERY USER S GUIDE Table 3 Color Clear and White Suspended Matter Trace Total Solids 100 00 Organic and Volatile Matter 50 0 Corrosion of positive plate Ammonia 8 0 Slight self discharge of both plates Antimony 5 0 Self discharge by local action reduces life lower on charge voltage 0 5 Self discharge can form poisonous Arsenic gas at negative Calcium 40 0 Increase of positive shedding Loss of capacity in both plates greater 5 0 loss in positive Copper 5 0 Increased self discharge lower on charge voltage 3 0 Increased self discharge at both ron plates lower on charge voltage Magnesium 40 0 Reduced life Nickel None Allowed Intense lowering of on charge voltage Nitrates 10 0 Increased sulfation at negative Corrosion at both plates loss of Nitrites 5 0 capacity reduced life Platinum None Allowed
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