User Guide

TROJAN BATTERY
24
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 identied within this procedure.
Please contact Trojan Battery Company’s technical support engineers at 800-423-6569 Ext. 3045 or
[phone] for help interpreting any test data.
9.1 .  Preparation for Testing
î If applicable, check that all vent caps are secured properly on the battery.
î 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 (60 ml of baking soda per liter
of water)]. Do not allow cleaning solution to get inside the battery. Rinse with water and dry with
a clean cloth.
î Check battery cables and connections. Replace any damaged cables. Tighten any loose
connections with an insulated wrench. Refer to Torque Values Section 3.5.
î For deep-cycle ooded/wet batteries, check the electrolyte level and add water if necessary.
Refer to Watering Section 4.2.
î Ensure batteries are fully charged before discharge testing to obtain accurate results.
9.2.Voltage Testing while Charging
î Disconnect and reconnect DC plug to restart charger.
î While the batteries are charging, record the current in the last ½ hour of the charge cycle
(if possible), and measure the battery set voltage.
î If the current at the end of the charge is below 5 amps, and the battery set voltage is above the
readings shown in Table 8, proceed to the step below to measure the on-charge voltages:
î If the end-of-charge voltage does not exceed these values, check the charger for proper output
and recharge the batteries. If the set voltages are still low, you may have a failed battery.
î While the batteries are on-charge, measure the individual battery voltages.
î Compare each voltage to the proper entry in Table 9. If any battery is below the appropriate
Minimum Voltage Threshold and the variation between all of the voltages is greater than the
Allowable Variation, the low battery may have failed.
Table 8
System/Battery Voltage 48V 36V 24V 12V 8V 6V
End-of-Charge Threshold Voltage 56V 42V 28V 14V 9.3V 7V