INSTALLATION AND OPERATION MANUAL fullriverbattery.com www.fullriverbattery.
CONGRATULATIONS ON YOUR PURCHASE OF A FULLRIVER BATTERY! Maximize the performance of your new battery by thoroughly reading this manual FULLRIVER BATTERY USA 4030 Adolfo Road Camarillo, CA 93012 Toll Free: (800) 522-8191 Int’l: (805) 484-7900 www.fullriverbattery.com This publication is protected by copyright. All rights are reserved. At no point, may any part of this publication be copied, reproduced, or transmitted by any means or any format without prior written consent from Fullriver Battery.
Table of Contents 1. GETTING STARTED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1.1 - Safety 1.2 - Equipment checklist 2. INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 2.1 - Selecting the appropriate cable size 2.2 - Terminal connections 2.3 - Battery orientation 2.4 - Series connections 2.5 - Parallel connections 2.6 - Series / parallel connections 2.
Notes Page d (800) 522-8191 Toll Free
INSTALLATION AND OPERATION MANUAL www.fullriverbattery.
Getting Started Before installing your Fullriver battery, please adhere to the following safety guidelines and make sure that you have the proper equipment for installation, operation and diagnostic testing. 1.1 - SAFETY PROTECT YOURSELF AND PROTECT YOUR BATTERY • Wear protective gear, including gloves, when handling a battery. • Install and remove a battery using the lifting handles provided. • Use a wrench with a rubber coated handle for installing, tightening, or removing battery connections.
Installation Proper battery installation is the first step in getting the best performance out of your Fullriver battery. 2.1 - SELECTING THE APPROPRIATE CABLE SIZE Cables must be sized to carry the maximum expected load. Under-sized cables can result in over-heating, melted connections and are a potential fire hazard. Refer to TABLE 1 below for the current carrying capacity by cable size. These values are for cable lengths of 6 feet (1.83 meters) or less.
Installation 2.2 - TERMINAL CONNECTIONS Terminal connections must be tightened using the correct torque values as defined in TABLE 2 below. Over or under tightened connections can result in terminal breakage, over-heating and/or meltdown. Using the proper torque value will provide optimum conductivity. To avoid a short circuit, use a wrench with an insulated or rubber coated handle when making terminal connections. See DIAGRAM 1 below for proper washer placement. Terminal Type ft-lbs in-lbs Nm 4.2 - 6.
Installation 2.3 - BATTERY ORIENTATION The ideal placement of batteries is upright. AGM batteries can be placed on their side if necessary. It is preferred that all the batteries within a pack be placed in the same orientation. NEVER place batteries in an inverted orientation. 2.4 - SERIES CONNECTIONS There is more than one option to meet your voltage requirements. For example, for a 12 volt system, you may use one (1) 12 volt battery or two (2) 6 volt batteries wired in a series to make up the 12 volts.
Installation 2.5 - PARALLEL CONNECTIONS There is more than one option to meet your energy requirements. For example, to meet the requirements for a 210 Amp-Hour system, you may use one (1) 210 Amp-Hour battery or two (2) 105 Amp-Hour batteries wired in parallel to make up the 210 Amp-Hours. Connect all the positive terminals together and all the negative terminals together in the string. See DIAGRAM 3 below for proper parallel connection.
Installation 2.7 - CROSS TYING BATTERIES IN PARALLEL PACKS In order to maintain balance in parallel battery packs, it is best to cross tie the batteries. This method of connection will maximize the performanceand life of your battery system. Cross-tying batteries means connecting positive to positives and negatives to negatives of each adjacent battery in the set. See DIAGRAM 5 below for proper cross tying connections. The dotted lines represent the cross tied cables.
Operation The performance and life of a battery will vary with the application, usage, temperature and depth of discharge. AGM batteries tend to deliver a higher capacity than rated (up to 10-15% higher) unitl they are broken in (approximately 30 cycles) and settle at their rated capacity. 3.
Operation 3.2 - OPERATING TEMPERATURE RANGE Recommended Maximum 5°F to 104°F -40°F to 160°F (-15°C to 40°C) (-40°C to 71°C) TABLE 4 3.3 - DEPTH OF DISCHARGE VS. BATTERY LIFE Battery cycle life will vary significantly depending on the depth of discharge. The deeper the depth of discharge, the fewer the cycles a battery will deliver. Conversely, the shallower the depth of discharge, the more cycles a battery will deliver (as shown in the chart below).
Charging Using the proper charger is critical to the performance and life of your AGM battery. If you are not sure if you have the right charger for AGM batteries, please call our technical support line at (800) 522-8191 or email help@fullriverbattery.com for verification. 4.1 - CHARGER INSPECTION 1. The charger cable should be insulated and free of breaks or cuts. 2. The cable connectors should be clean and properly mated with the battery terminals to ensure a snug connection. 3.
Charging 4.4 - CHARGING PARAMETERS Most chargers come pre-set from the factory. If your charger is pre-programmed, use the information below to check if the settings are compatible with AGM batteries. If you have a programmable charger or inverter, use the following information for settings. 4.4.1 - CURRENT The recommended bulk current is 20% of the 20 Hr. AH capacity or 0.20 x C20 (20 Hr. capacity in AH). Example: DC115-12 is rated at 115AH @ 20 Hrs. The recommended bulk current is 0.
Storage AGM batteries have a much longer shelf life than wet, lead-acid batteries. With a selfdischarge of only 1-3% per month, AGM batteries can be stored for a year or longer without needing to be charged. 5.1 - BATTERY STORAGE PROCEDURE 1. Charge batteries before they are placed in storage. 2. Disconnect batteries from the equipment and charger to eliminate any parasitic loads. 3. Check the batteries based on conditions and schedule in TABLE 8 below.
Storage 5.2 - TEMPERATURE EFFECTS ON SELF-STORAGE If the storage environment is hot, batteries will self-discharge faster than in a cold environment as shown in CHART 3 below. Batteries CAN be safely stored on concrete floors without any negative effects. Concrete floors DO NOT drain batteries. 5.3 - STORAGE TEMPERATURE RANGE Recommended Maximum 5°F to 122°F (-15°C to 50°C) -40°F to 160°F (40°C to 71°C) TABLE 10 Store batteries in a cool, dry environment to minimize self discharge. www.
Testing Testing batteries can be complex and there are many application specific variables that cannot be considered in one simple test. This section is a guide to help you determine the overall condition of your batteries. Contact your local Fullriver Battery distributor for assistance. 6.1 - TEST PREPARATION 1. Check that the battery cables are in good working condition. Replace any damaged or broken cables. 2.
Testing 3. If the set runs more than 50% of its rated capacity, the batteries are good and the test is complete. 4. If the set runs less than 50% of its rated capacity, reconnect the discharger. While under the discharge load, record the end of the discharge voltage for each battery. 5. The batteries that are 0.5V lower than the highest end of discharge voltage should be noted. 6. If the set delivered less than 50% of its rated capacity, and the same batteries that were noted in STEP 3 of SECTION 6.
Your Clean-Green Energy Solution 7.1 - FULLRIVER PRODUCTS Fullriver Battery produces sealed, maintenance-free batteries that are nonhazardous, non-spillable and are made from approximately 80% recycled materials. During normal operation, our batteries will not release any harmful gasses and will not leak any acidic electrolyte into the environment. Fullriver batteries are classified as safe for air, sea, and ground transportation. They meet all requirements of the International Air Transport Association (I.
Your Clean-Green Energy Solution 7.3 - BATTERY RECYCLING www.fullriverbattery.
Transportation Information Fullriver batteries are sealed lead-acid batteries made with Absorbant Glass Mat (AGM) technology. The electrolyte is absored into the fiberglass separator material rather than in a free-flowing liquid form. Fullriver batteries are non-spillable electric storage batteries. They are exempt from the requirements of DOT’s hazardous materials regulations since they adhere to the requirements of code 49 CFR Section 173.
Appendix A.1 - TEMPERATURE RANGES Condition Recommended Maximum Storage 5°F to 122°F (-15°C to 50°C) -40°F to 160°F (-40°C to 71°C) Operation 5°F to 104°F (-15°C to 40°C) -40°F to 160°F (-40°C to 71°C) Charge with TC 5°F to 122°F (-15°C to 50°C) -40°F to 160°F (-40°C to 71°C) Charge w/o TC 32°F to 104°F (0°C to 40°C) 5°F to 122°F (-15°C to 50°C) A.2 - STATE OF CHARGE (S.O.C) VS. OPEN CIRCUIT VOLTAGE (O.C.V.) Open Circuit Voltage (O.C.V.) State of Charge (S.O.C.) 2V 6V 8V 12V 100 2.
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