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 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. TECHNICAL SUPPORT 800-423-6569 Ext.
Contents 01 Equipment Needed . . . . . . . . . . . 5 02 Battery Installation . . . . . . . . . . . 5 04 Storage . . . . . . . . . . . . . . . . . 16 4.1 Storage in Hot Environments . . . . . . . . . 17 4.2 Storage in Cold Environments . . . . . . . . 17 2.1 Safety . . . . . . . . . . . . . . . . . . 5 2.2 Battery Connections . . . . . . . . . . . . 5 05 How to Maximize the Performance of your Trojan Battery . .
01 Equipment Needed Before installation or maintenance of your batteries, have the following equipment available: îî Goggles and gloves îî Distilled or treated water (i.e. de-ionized, reverse osmosis, etc.
2.2 Battery Connections (continue from pg 5) If using washers, it is very important to ensure the battery wire connection is contacting the lead surface of the terminal and the washer is placed on top of the wire connection. If you place the washer between the terminal lead and the battery wire, this creates high resistance and can cause terminal meltdown. 2.2.1 Cable Size Battery cables should be sized to handle the expected load.
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.
2.4 Connecting Batteries to Increase System Power You can increase capacity and voltage, or both, by configuring your batteries as follows: 2.4.1 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 225 Amp-Hours (AH) connected in series System Voltage: 6V + 6V = 12V System Capacity = 225AH 2.4.
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 Deep-cycle flooded/wet batteries must be placed upright at all times.
03 Preventative Maintenance 3.1 Inspection îî 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 3.3. îî If fluids are on the top of a deep-cycle flooded/wet battery this may mean that the battery is being over-watered or overcharged. Refer to Watering section 3.2 for the proper watering procedure.
Table 3 Recommended Maximum Allowable Impurities in Water for Battery Use Impurity Parts Per Million Effects of Impurity 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 Arsenic 0.5 Self-discharge, can form poisonous gas at negative Calcium 40.
3.3 Cleaning (continue from pg 11) îî Rinse with water and dry with a clean cloth. îî Apply a thin coat of terminal protector spray that can be purchased through your local battery dealer. îî Keep the area around batteries clean and dry. 3.4 Charging & 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.
Table 4 Charger Voltage Settings for Deep-Cycle Flooded/Wet Batteries System Voltage 6 Volt 8 Volt 12 Volt 24 Volt 36 Volt 48 Volt Daily Charge 7.4 9.87 14.8 29.6 44.4 59.2 Absorption Charge for RE Applications 7.05 – 7.35 9.4 – 9.8 14.1 – 14.7 28.2 – 29.4 42.3 – 44.10 56.4 – 58.8 Float Charge 6.6 8.8 13.2 26.4 39.4 52.8 Equalize Charge 7.8 10.4 15.5 31.0 46.5 62.
Table 5 Charger Voltage Settings for Deep-Cycle AGM Batteries System Voltage 6 Volt 8 Volt 12 Volt 24 Volt 36 Volt 48 Volt Daily Charge 6.9 – 7.2 9.2 – 9.6 13.8 – 14.4 27.6 – 28.2 41.4 – 42.3 55.2 – 56.4 Absorption Charge for RE Applications 7.05 – 7.35 9.4 – 9.80 14.1 – 14.7 28.2 – 29.4 42.3 – 44.1 56.4 – 58.8 Float Charge 6.75 9.0 13.5 27 40.
Table 6 Charger Voltage Settings for Deep-Cycle Gel Batteries System Voltage 6 Volt 8 Volt 12 Volt 24 Volt 36 Volt 48 Volt Daily Charge 6.9 – 7.2 9.2 – 9.6 13.8 – 14.4 27.6 – 28.2 41.4 – 42.3 55.2 – 56.4 Absorption Charge for RE Applications 7.05 – 7.2 9.4 – 9.6 14.1 – 14.4 28.2 – 28.8 42.3 – 43.2 56.4 – 57.6 Float Charge 6.75 9.0 13.5 27 40.
3.4.2 Equalizing (deep-cycle flooded/wet batteries only) Equalizing is an overcharge performed on deep-cycle flooded/wet batteries after they have been fully charged. Trojan recommends equalizing only when batteries have low specific gravity, below 1.235 or wide ranging specific gravity, > 0.030 points between cells, after fully charging a battery. Deep-cycle AGM or gel batteries should never be equalized. îî îî îî îî îî îî Confirm that the batteries are deep-cycle flooded/wet.
Table 7 State of Charge as a Measure of Specific Gravity and Open-Circuit Voltage Open Circuit Voltage Percentage Charge Specific Gravity 100 1.277 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 10 1.073 1.918 5.75 7.67 11.
05 How to Maximize the Performance of your Trojan Battery îî Follow all the procedures in this User’s Guide for proper installation, maintenance and storage. îî Do not discharge your battery more than 80%. This safety factor will eliminate the chance of overdischarging and damaging your battery. îî If you have any questions or concerns about battery care, please contact Trojan Battery Company’s technical support engineers at 800-423-6569 Ext. 3045 or +1-562-236-3045 before a problem develops.
07 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. 7.1 Preparation for Testing îî Check that all vent caps are secured properly on the battery.
7.3 Specific Gravity Testing (continue from pg 19) 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; recharge batteries. îî If any battery has a specific gravity variation of more than 0.030 between cells equalize the set. îî If there is still a variation there may be a failed battery. 7.
08 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, at www.trojanbattery.com, to read how to properly recycle your batteries.
09 Battery Acronyms AGM Absorbed Glass Mat °F Fahrenheit amp Amperage Ind Industrial Terminal Ah Amp-Hours It Insert Terminal awg American Wire Gauge Lt L-Terminal Ap Automotive Post Terminal Mc Corrected Minutes °C Celsius Mr Minutes Recorded c.c.a.
Trojan Battery Company would like to thank you for selecting our battery. With over 85 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 atte r y C om 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.com © 2013 Trojan Battery Company.
call 800.423.6569 or + 1.562.236.3000 or visit www.trojanbattery.com 12380 Clark Street, Santa Fe Springs, CA 90670 • USA © 2013 Trojan Battery Company. 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. Trojan Battery Company reserves the right to make adjustments to this publication at any time, without notices or obligation.
