INSTALLATION AND OPERATION MANUAL fullriverbattery.
CONGRATULATIONS ON YOUR PURCHASE OF A FULLRIVER BATTERY! Maximize the performance of your new battery by thoroughly reading this manual. FULLRIVER BATTERY 3823 Mission Oaks Blvd, Ste A 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.
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.
Installation 2.3 - BATTERY ORIENTATION The ideal placement of batteries is upright. AGM and Gel 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 (terminals pointed towards ground). 2.4 - SERIES CONNECTIONS There is more than one option to meet your voltage requirements.
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 performance and 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 and Gel batteries tend to deliver a higher capacity than rated (up to 10-15% higher) until they are broken in (approximately 30 cycles) and settle at their rated capacity. 3.
Operation 3.3 - LOW DISCHARGE RATE EFFECTS Battery cycle life will be reduced when the constant load applied in a cyclic application is at or below 0.7% of the total Ah in the battery bank (C20 rating). This is due to a higher rate of sulfation occuring in the middle of the plate that will cause a reduction in available capacity which in turns increases the depth of discharge over time. An effort to either increase the load above 0.
Charging Using the proper charger is critical to the performance and life of your AGM or Gel battery. If you are not sure if you have the right charger for AGM or Gel 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 4.4.1 - CURRENT All Models (excl. FSG): The recommended bulk current is 20-25% of the 20 Hr AH capacity or 0.20 x C20 (20 Hr. capacity in AH). The maximum allowable bulk current is 35% of the 20 Hr. AH capacity or 0.35 x C20 (20Hr. capacity in AH), unless specified. Example: DC115-12 is rated at 115AH @ 20 Hrs. The recommended bulk current is 0.20 x 115 = 23 Amps The maximum bulk current is 0.35 x 115 = 40 Amps FSG Series: The recommended bulk current is 12.5% of the 10 Hr. AH capacity or 0.
Storage AGM and Gel batteries have a much longer shelf life than wet, lead-acid batteries. With a self-discharge of only 1-3% per month, AGM and Gel 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 9 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 the chart below. The FSG series will discharge approximately 40-60% slower above 86°F than the chart below indicates. Batteries CAN be safely stored on concrete floors without any negative effects. Concrete floors DO NOT drain batteries. 5.
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 60% of its rated capacity, the batteries are good and the test is complete. 4. If the set runs less than 60% 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 60% of its rated capacity, and the same batteries that were noted in STEP 3 of SECTION 6.
Testing & Your Clean-Green Energy Solution 6.6 - BATTERY REPLACEMENT INSTRUCTIONS As long as it is safe to do so, charge the set of batteries before replacing the failed ones to make sure the good batteries are fully charged. If possible, replace failed batteries with good batteries around the same age from another piece of equipment. Try to avoid mixing new batteries in equipment with old batteries. Put all new batteries in the same piece of equipment. 7.
Your Clean-Green Energy Solution 7.3.2 - ABSORPTION SETTINGS Absorption time varies per installation according to total bank size and total PV kW. Our maximum absorption time is 4 hours, however most installations need 2-3 hours on average. To estimate your rough absorption time, use the following formula: [(AH * DOD) / CHARGE AMPS * 0.
Transportation Information Fullriver DC, Full Force, and Full Throttle batteries are sealed lead-acid batteries made with Absorbent Glass Mat (AGM) technology. The electrolyte is absorbed into the fiberglass separator material rather than in a free-flowing liquid form. Fullriver DCG and FSG batteries are sealed lead-acid batteries made with gelled electrolyte technology. The electrolyte is suspended in a thixotropic gel applied to the plates rather than in a free-flowing liquid form.
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.
fullriverbattery.com 3823 Mission Oaks Blvd, Ste A Camarillo, CA 93012 800.522.8191 (Toll Free) 805.484.
