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. Our goal is to provide reliable energy storage solutions that enhance the way people live and work around the world.
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. www.trojanbattery.com TECHNICAL SUPPORT 800-423-6569 Ext. 3045 / +1-562-236-3045 technical@trojanbattery.
Contents 1 Safety . . . . . . . . . . . . . . . . . . 5 2 Equipment Needed . . . . . . . . . . . 5 3 Battery Installation . . . . . . . . . . . 6 6 6.1. Storage in Hot Environments . . . . . . . . 21 6.2. Storage in Cold Environments . . . . . . . . 21 7 Maximizing the Performance of Your Trojan Battery . . . . . . . . . . 23 3.1. Battery Connections . . . . . . . . . . . . 6 3.2. Terminal Types . . . . . . .
1 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.
3 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, terminal damage, meltdown, or fire. To ensure proper connections, please use the following guidelines for cable size, torque values and terminal protection. 3.2.
Figure 2 Flooded Battery Terminal Configurations 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 Cable Lug Nut - Torque to 95-105 (in-lbs), 11-12 (Nm) Washer* Nut - Torque to 95-105 (in
Figure 3 AGM Battery Terminal Configurations LT Nut - Torque to 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 (MOTIVE AGM WITH C-MAX) Nut - Torque to 95-105 (in-lbs), 11-12 (Nm) Cable Lug Lock Washer AP Terminal AP Connector Lock Washer Bolt - Torqu
Gel Battery Terminal Configurations 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 amperage based on the cable/wire gauge size. Table 1 10 Cable/Wire Gauge Size, AWG (mm2) Ampacity (amps) 14 (2.08) 20 T R O 12 (3.31) 25 10 (5.26) 35 8 (8.36) 50 6 (13.3) 65 4 (21.1) 85 2 (33.6) 115 1 (42.4) 130 1/0 (53.5) 150 2/0 (67.4) 175 4/0 (107) 230 J A N B A T T E R Table values are from NEC Table 310.
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 in Banks You can increase capacity and voltage, or both, by configuring your batteries as shown in Table 3.
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 battery-specific information helpful in determining ventilation needs, please contact Trojan Battery Company’s technical support engineers. 3.9.
4 Preventive Maintenance 4.1. Inspection îî E xamine the outside appearance of the battery. The tops of the batteries and terminal connections should be clean, dry, and free of corrosion. Refer to Section 4.3, Cleaning. 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 Section 4.2, Watering, for the proper watering procedure.
r Table 4 Water Impurity Limits Impurity Parts Per Million Effects of Impurity Color 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 0.50 Self-discharge, can form poisonous gas at negative plate Calcium 40 Increase of positive plate shedding Chloride 5.
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 For flooded batteries, check that all vent caps are secured properly on the battery.
5.2.1. Charging Flooded Batteries îî Prior to charging, check electrolyte levels to verify that the plates are covered with electrolyte. If plates are exposed, add enough water (distilled or deionized) to just cover the plates prior to charging. îî Make sure that vent caps are in place and are properly secured.
Figure 6 Recommended Deep-Cycle Flooded/Wet Charging Profile Voltage (per cell) Current (Amps) Charge Current 10-13% C20 2.45V to 2.70V (@25°C, 77°F) 2.45V (@25°C, 77°F) Charge Voltage 1-3% C20 20% 90% 100% State of Charge (%) Note: Charging time will vary depending on battery size, charger output, and depth of discharge. 5.2.2. C harging Valve-Regulated Lead Acid (VRLA) Batteries (AGM and gel) There are various ways to charge VRLA batteries.
îî I n applications where batteries are infrequently used, it is desirable to compensate for self-discharge by keeping a low charging voltage on the batteries. This is called the float voltage. Avoid using continuous float charging on VRLA batteries that are charged more than once/month. When float charging is used, it is started immediately after the end of the finish stage. îî VRLA charging voltages should always be temperature compensated per Table 6.
Figure 8 Recommended Trojan Deep-Cycle Gel Charging Profile Voltage (per cell) Current (Amps) Charge Current 10-13% C20 2.40V (@25°C, 77°F) Charge Voltage 20% 80% 100% State of Charge (%) Note: Charging time will vary depending on battery size, charger output, and depth of discharge. 5.3. Equalizing (flooded/wet batteries only) When batteries are used in a battery bank, over time some of the batteries can drift to a lower state of charge than others.
6 Storage The following tips will help ensure that your batteries emerge from storage in good condition: îî Charge batteries before placing them in storage. îî Store in a cool and 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 open-circuit voltage of flooded batteries every 4 - 6 weeks.
Table 7 FLOODED/WET STATE OF CHARGE AS A FUNCTION OF SPECIFIC GRAVITY AND OPEN-CIRCUIT VOLTAGE STATE OF 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.
Maximizing the Performance of Your Trojan Battery îî îî îî 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 peak capacity. îî Trojan’s deep-cycle AGM and gel batteries will reach rated capacity in less than 20 cycles. îî Trojan’s deep-cycle flooded batteries take 50 - 100 cycles to achieve full, peak capacity.
9 Troubleshooting 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 +1-562-236-3045 for help interpreting any test data. 9.1. Preparation for Testing îî If applicable, check that all vent caps are secured properly on the battery.
Table 9 ON-CHARGE TEST THRESHOLDS MINIMUM VOLTAGE THRESHOLD ALLOWABLE VARIATION WITHIN A SET 6V 7V 0.5V 8V 9.3V 0.7V 12V 14V 1.0V NOMINAL BATTERY VOLTAGE 9.3. Specific Gravity (flooded/wet batteries only ) îî îî îî Use a reliable, high-quality hydrometer for specific gravity measurements. Fill and drain the hydrometer 2 - 3 times before drawing a sample from the battery. Measure specific gravity readings for all battery cells.
9.5. Discharge Testing îî Follow the procedure below to determine battery capacity. îî Ensure the battery set has been fully recharged before testing. îî Prior to running a discharge test, ensure that all charging sources and loads are disconnected from the batteries. îî Connect and start discharger. îî Record the runtime (minutes) when discharge is complete. îî Correct runtime minutes for temperature using one of the following formulas*. o F or temperature measurements in Fahrenheit Mc = Mr [1 – 0.
10 Battery Recycling Lead acid batteries are the environmental success story of our time. Per the International Lead Association, in Europe and the USA, 99% of all battery lead is recycled. In fact, lead acid batteries top the list as 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.
11 Battery Abbreviations AGM Absorbed Glass Mat EUT Embedded Universal Terminal A Ampere °F Degrees Fahrenheit Ah Ampere-hour IND Industrial Terminal AWG American Wire Gauge LT L-Terminal AP Automotive Post Terminal M6/M8 6mm/8mm terminal °C Degrees Celsius Mc Minutes Corrected C.C.A.
Notes U S E R ’ S G U I D E 29
Notes 30 T R O J A N B A T T E R Y
U S E R ’ S G U I D E 31
Trojan Battery Company would like to thank you for selecting our battery. With close to 100 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 RO JA N BAT T E RY C O M PA N Y 10375 Slusher D rive, S ant a Fe Springs , C A 9 0 670 USA Call 8 0 0 - 4 2 3 - 6 5 6 9 E x t . 3 0 4 5 or +1- 5 6 2-2 3 6 - 3 0 4 5 or v isit w w w.t r oj a n b a t t e r y.
