U S E R ’ S G U I D E
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.
This User’s Guide was created by Trojan’s application 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. TECHNICAL SUPPORT 800-423-6569 Ext.
Contents 01 Safety . . . . . . . . . . . . . . . . . . 5 02 Equipment Needed . . . . . . . . . . . 5 03 Battery Installation . . . . . . . . . . . 6 3.1 Battery Connections . . . . . . . . . . . . . 6 07 What to Expect from your Trojan Battery . 25 08 Trouble-Shooting . . . . . . . . . . . . 26 3.2 Terminal Types . . . . . . . . . . . . . . . 6 3.4 Cable Size . . . . . . . . . . . . . . . . 10 8.
01 Safety Since batteries deliver large amounts of power that can cause injury and even death, observing safety rules is of paramount importance. For your safety and the safety of those around you, please observe the following checklist when working on or around batteries.
03 Battery Installation To ensure you install your batteries properly and safely, please use the following guidelines. 3.1 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. 3.
Flooded ELPT EUT Cable Lug Nut - Torque to 95-105 in-lbs (11-12 Nm) Washer* Terminal Bolt Nut - Torque to 95-105 in-lbs (11-12 Nm) Washer* Cable Lug Terminal EHPT EAPT Nut - Torque to 95-105 in-lbs (11-12 Nm) Washer* Stud Portion Terminal AP Connector AP Connector Torque to 50-70 in-lbs (6-8 Nm) Terminal Torque to 50-70 in-lbs (6-8 Nm) Cable Lug DT LT Nut - Torque to 95-105 in-lbs (11-12 Nm) Washer* Cable Lug Bolt Terminal Cable Lug Nut - Torque to 95-105 in-lbs (11-12 Nm) Washer* AP Terminal
AGM LT Nut - Torque to 55-70 in-lbs (6-8 Nm) Washer Cable Lug Bolt - 20 mm M8 Terminal Bolt - 16mm - Torque to 85-95 in-lbs (10-11 Nm) Lock Washer LT Adapter Lock Washer M6 DT Torque to 50-70 in-lbs (6-8 Nm) Washer Stud Terminal M8 Lock Washer Bolt - Torque to 25-35 in-lbs (3-4 Nm) Washer Cable Lug Terminal AP (RELIANT) Nut - Torque to 95-105 in-lbs (11-12 Nm) Cable Lug Lock Washer AP Terminal AP Connector Lock Washer Bolt - Torque to 85-95 in-lbs (10-11 Nm) Washer Cable Lug Terminal AP AP Connec
Gel LT UT Nut - Torque to 95-105 in-lbs (11-12 Nm) Cable Lug Washer* Terminal Bolt Washer* Nut - Torque to 95-105 in-lbs (11-12 Nm) Terminal Cable Lug Bolt DT AP Nut - Torque to 95-105 in-lbs (11-12 Nm) Cable Lug Washer* AP Terminal AP Connector AP Connector Torque to 50-70 in-lbs (6-8 Nm) Terminal Torque to 50-70 in-lbs (6-8 Nm) Stud Terminal Images shown reflect correct hardware placement. *Hardware not supplied by Trojan Battery Company.
3.4 Cable Size Battery cables should be sized to handle the expected load. Refer to Table 1 for the maximum amps based on the cable/wire gauge size. Table 1 10 Cable/Wire Gauge Size (AWG) Ampacity (amps) 14 25 12 30 10 40 8 55 6 75 4 95 T R O J 2 130 1 150 1/0 170 2/0 265 4/0 360 A N B A T T E R Table values are for cable lengths less than 6 feet (1829 mm).
3.5 Torque Values Tighten all cable connections to the proper specification to make sure there is good contact with the terminals. Over-tightening terminal connections can cause terminal breakage and loose connections can result in terminal meltdown or fire. Refer to Table 2 for the proper torque values based on the type of terminal on your battery.
3.6 Terminal Protection Corrosion can build up on terminals if they are not kept clean and dry. To prevent corrosion, after tightening the fasteners, apply a thin coat of terminal protector spray that can be purchased through your local battery dealer. 3.7 Connecting Batteries to Increase System Power You can increase capacity and voltage, or both, by configuring your batteries as follows: Series Connect Parallel Connect Series/Parallel Connect To increase voltage, connect batteries in series.
3.8 Ventilation Deep-cycle flooded/wet lead acid batteries release small amounts of gas during usage, particularly during the charging process. Deep-cycle AGM and gel batteries do release gas, but at a much lower rate than the flooded types. It is critical to charge batteries in a properly ventilated area. For more assistance in determining ventilation needs, please contact Trojan Battery Company’s technical support engineers. 3.
04 Preventative Maintenance 4.1 Inspection îî Examine the outside appearance of the battery. The tops of the batteries and terminal connections should be clean and dry, as well as free of dirt and corrosion. Refer to Cleaning Section 4.3. îî If fluids are present on the top of a deep-cycle flooded/wet battery, it may mean that the battery is being over-watered or overcharged. Refer to Watering Section 4.2 for the proper watering procedure.
Table 3 Recommended Maximum Allowable Impurities in Water for Battery Use Parts Per Million Effects of Impurity Color Impurity Clear and “White” - Suspended Matter Trace - Total Solids 100 Organic and Volatile Matter 50 Corrosion of positive plate Ammonia 8.0 Slight self-discharge of both plates Antimony 5.0 Increased self-discharge, reduces life, lower on-charge voltage Arsenic 0.
4.3 Cleaning Check the battery for cleanliness at regular intervals and keep terminals and connectors free of corrosion. Terminal corrosion may adversely affect the performance of the battery and present a safety hazard. îî Check that all vent caps are secured properly on the battery. îî Clean the top of the battery, terminals and connections with a cloth or brush, and a solution of baking soda and water (1 cup of baking soda to 1 gallon of water).
AGM / Gel Batteries Similarly, two methods can be used to boost your AGM/gel product, automatically or manually. If using the automatic method (charger is preprogrammed), just allow the charger to go through the complete charge cycle. Make sure the proper battery type, AGM or gel, is selected on the charger. If you use the manual method (charger has adjustable settings) follow the steps below: îî Boost charge at a CONSTANT VOLTAGE of (2.40 V/cell) with the current limited to 20% of C₂₀.
4.4.2 Charging Proper charging is imperative to maximize battery performance. Both under- or over-charging batteries can significantly reduce the life of the battery. Most chargers are automatic and pre-programmed, while others are manual and allow the user to set the voltage and current values. AGM and gel batteries should always have temperature compensated charging. îî Batteries should be fully charged after each use. “Use” is defined as at least 30 minutes of runtime.
Table 4 Deep-Cycle Flooded/Wet Batteries - Charger Voltage Settings @ 25°C (77°F) System Voltage 6 Volt 8 Volt 12 Volt 24 Volt 36 Volt 48 Volt 7.41 9.88 14.82 29.64 44.46 59.28 7.05 – 7.35 9.40 – 9.80 14.10 – 14.70 28.20 – 29.40 Finish Charge (2.70 VPC) 8.10 10.80 16.20 32.40 48.60 64.80 Equalize Charge (2.70 VPC) 8.10 10.80 16.20 32.40 48.60 64.80 Float Charge (if desired 2.25 VPC) 6.75 9.00 13.50 27.00 40.50 54.00 Bulk Charge (2.47 VPC) Absorption Charge (2.35 – 2.
Table 5 Deep-Cycle AGM Batteries - Charger Voltage Settings** System Voltage 6 Volt 8 Volt 12 Volt 24 Volt 36 Volt 48 Volt 7.20 9.60 14.40 28.80 43.20 57.60 7.05 – 7.35 9.40 – 9.80 14.10 – 14.70 Finish Charge (2.45 VPC) 7.35 9.80 14.70 29.40 44.10 58.80 Float Charge (2.25 – 2.3 VPC) 6.75 9.00 13.50 27.00 40.50 54.00 Bulk Charge (2.40 VPC) Absorption Charge (2.35 – 2.45 VPC) 28.20 – 29.40 42.30 – 44.10 56.40 – 58.
Table 6 Deep-Cycle Gel Batteries - Charger Voltage Settings** System Voltage 6 Volt 8 Volt 12 Volt 24 Volt 36 Volt 48 Volt Bulk Charge (2.40 VPC) 7.20 9.60 14.40 28.80 43.20 57.60 Float Charge (if desired 2.25 VPC) 6.75 9.00 13.50 27.00 40.50 54.00 ** Gel batteries should always use temperature compensated charging per the following rule: 5.0 mV per cell / °C or 2.8 mV per cell / °F Subtract 0.005 volt per cell from the voltage reading for every 1°C above 25°C, or add 0.
4.4.3 Equalizing (deep-cycle flooded/wet batteries only) Equalizing is an overcharge performed after fully charging deep-cycle flooded/wet batteries. An equalizing charge prevents battery stratification and reduces sulfation which are leading causes of battery failure. Trojan recommends equalizing every 30 days or when batteries have a low specific gravity reading after fully charging, below 1.235, or have a wide ranging specific gravity of >0.030 points between cells. Reference Section 8.
Table 7 Flooded/Wet State of Charge as a Measure of Specific Gravity and Open-Circuit Voltage Percentage Charge Specific Gravity Cell 6 Volt 8 Volt 12 Volt 100 1.277 2.122 6.37 8.49 12.73 90 1.258 2.103 6.31 8.41 12.62 80 1.238 2.083 6.25 8.33 12.50 70 1.217 2.062 6.19 8.25 12.37 60 1.195 2.04 6.12 8.16 12.24 50 1.172 2.017 6.05 8.07 12.10 40 1.148 1.993 5.98 7.97 11.96 30 1.124 1.969 5.91 7.88 11.81 20 1.098 1.943 5.83 7.77 11.66 1.073 1.918 5.
05 Storage îî Charge batteries before placing in storage. îî Store in a cool, dry location, protected from the elements. îî Disconnect from equipment to eliminate potential parasitic loads that may discharge the battery. îî Batteries gradually self-discharge during transit and storage, so monitor the specific gravity or voltage in flooded batteries every 4 - 6 weeks. Monitor the open circuit voltage for AGM or gel batteries every 2 - 3 months.
07 What to Expect from your Trojan Battery îî A new deep-cycle battery will not immediately deliver its full rated capacity. This is normal and should be expected since it takes time for a deep-cycle battery to reach maximum performance or peak capacity. îî Trojan’s deep-cycle AGM and gel batteries will reach rated capacity in less than 10 cycles. îî Trojan’s deep-cycle flooded batteries take between 50 – 100 cycles to achieve full, peak capacity.
08 Trouble-Shooting These battery testing procedures are guidelines only for identifying a deep-cycle 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 Ext. 3045 or +1-562-2363045 for help interpreting the test data. 8.1 Preparation for Testing îî Check that all vent caps are secured properly on the battery.
8.3 Specific Gravity (flooded/wet batteries only) îî Fill and drain the hydrometer 2 - 3 times before drawing a sample from the battery. îî Measure specific gravity readings for all battery cells. îî 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). îî If every cell in the battery set is below 1.235, the batteries may be undercharged and require recharging.
8.5 Discharge Testing îî îî îî îî Follow the procedure below to determine battery capacity. Connect and start discharger. Record the runtime (minutes) when discharge is complete. Correct runtime minutes for temperature using the following formula (valid between 75°F (24°C) and 90°F (32°C): Mc = Mr [1 – 0.005* (T1 - 80*)] *(For Celsius, use 0.
09 Battery Recycling Lead acid batteries are the environmental success story of our time since more than 97% of all battery lead is recycled. In fact, lead acid batteries top the list as one of the most highly recycled consumer products. Trojan Battery supports proper recycling of your battery to keep the environment clean. Please contact your nearest Trojan Distributor, at www.trojanbattery.com, to learn how to properly recycle your batteries.
10 Battery Acronyms AGM Absorbed Glass Mat AMP Ampere EUT °F Degrees Fahrenheit AH Amp-Hours IND Industrial Terminal AWG American Wire Gauge LT L-Terminal Embedded Universal Terminal AP Automotive Post Terminal M6/M8 6mm - 8mm Teminal °C Degrees Celsius Mc Corrected Minutes C.C.A.
Trojan Battery Company would like to thank you for selecting our battery. With over 90 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. T R O J A N B AT T E R Y C O M PA N Y 12380 Clark Street, Santa Fe Springs, CA 90670 USA Call 8 0 0 - 423 - 6569 E x t . 30 45 or +1-562-236 -30 45 or V isit w w w.trojanb at ter y.
Trojan batteries are available worldwide through Trojan’s Master Distributor Network. We offer outstanding technical support, provided by full-time application engineers. t r o j a n b a t t e r y. c o m 800.423.6569 or + 1.562.236.3000 12380 Clark Street, Santa Fe Springs, CA 90670 • USA © 2016 Trojan Battery Company, LLC. All rights reserved. Trojan Battery Company is not liable for damages that may result from any information provided in or omitted from this publication, under any circumstances.
