SOLAR INDUSTRIAL LINE USER’S GUID 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. 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.
CONTENTS 1 SAFETY ....................................................5 6 STORAGE ................................................... 22 2 EQUIPMENT NEEDED ................................. 6 6.1. Storage in Hot Environments .................................. 22 6.2. Storage in Cold Environments ................................ 23 3 BATTERY INSTALLATION........................... 6 7 MAXIMIZING THE PERFORMANCE 3.1. Inspection ............................................................... 6 3.2.
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.
2 EQUIPMENT NEEDED Before installation or maintenance of your batteries, have the following equipment available: î Proper Personal Protective Equipment (PPE) (eye protection, acid-resistant gloves, and appropriate footwear) î Distilled or deionized water î Insulated tools î Sodium Bicarbonate Solution: 1 cup of baking soda to 1 gallon of water (60 ml of baking soda per liter of water) î Terminal protectant (NO-OX-ID™ grease or a high-quality spray) î Voltmeter î Hydrometer î Battery charger 3 BATTERY INS
Cables* Vent Cap Terminal Protector Handles Outer Case *Trojan recommends using UL listed cables, such as Trojan’s premium-quality maroon cables. 3.2 BATTERY CO N N EC TI O N S 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.
3.4 . CO RREC T H ARD WARE IN STALLATI O N When using flat washers, it is very important to ensure the battery cable lug is contacting the lead surface of the terminal, and the washer is placed on top of the lug. Do not place a washer between the battery terminal and the lug, as this will create high resistance and cause excessive heating of the connection and terminal. It is important that fasteners be tightened to the appropriate torque.
î î î î Place the stainless steel split spring washer on the end of the bolt that is protruding through the terminal, against the flat washer. Install the hex stainless steel M8 nut on the bolt and tighten the nut with your fingers. Do not torque the bolts until all the cables are installed to allow some adjustment of position. After all connections are assembled, torque all stainless steel connector bolts to 100-120 in-lbs (11-14 Nm).
3.5. 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. Note that Trojan Battery supplies a single maroon 4/0 cable with each Solar Industrial battery, which will be sufficient for all of the inter-battery connections. TABLE 1 Cable/ Wire Gauge Size, AWG (mm2) Ampacity (amps) 14 (2.08) 20 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.
3.7. TERM IN AL PRO TEC TI O N Trojan Solar Industrial batteries include terminal protectors for the purpose of keeping the terminals clean and dry in order to avoid corrosion and short-circuiting. Cable installation requires the removal of the terminal protectors which involves the following steps: Knockouts Latch î î î î î î î î The protector has two locating pins that fit through the holes of the terminal.
3.8 . CO N N EC TIN G BATTERIES IN BAN KS You can increase capacity and voltage, or both, by configuring your batteries as shown in Table 2. TABLE 2 SERI ES CO N N EC TI O N EXAMPLE To increase voltage, connect batteries in series. This will not increase the system capacity. Twelve SIND 02 2450 batteries connected in series System Voltage = 2V x 12 = 24V System Capacity = 2450Ah (C100) PARALLEL CO N N EC TI O N EXAMPLE To increase capacity, connect batteries in parallel.
SERI ES/ PARALLEL CO N N EC TI O N Note: maximum of three parallel strings without a Battery Management System EXAMPLE To increase both voltage and capacity, connect additional batteries in series and parallel. Twenty-four SIND 02 245, 2V batteries rated at 2450Ah Connected in Series/Parallel System Voltage 2V x 12 = 24V System Capacity = 2450Ah + 2450Ah = 4900Ah (C100) 3.9.
3.12. TEM PERATU RE The recommended operating temperature range for Solar Industrial batteries is -4°F to 113°F (-20°C to +45°C). Note that battery life diminishes as temperature increases, while capacity increases with temperature. It is important to minimize temperature variations between the cells. Therefore, avoid restricting airflow by tightly packing batteries together. The batteries should have a minimum of 1.00” (25.4 mm) of space between them to allow for adequate airflow. 3.
4 PREVENTIVE MAINTENANCE 4 .1. IN SPEC TI O N The following procedures define the recommended schedule for proper maintenance and record keeping. Readings should be taken when the batteries are at full state of charge and not under load (open-circuit). The Trojan Solar Industrial warranty requires that records be kept on the Battery Maintenance Log Sheet (included in this Guide) and is available for download on our website at https://www.trojanbattery.com/literature.
4 .2. WATERIN G ( FLO O D ED / WET BATTERIES O N LY) Deep-cycle flooded/wet batteries need to be watered periodically. The frequency depends on battery usage, charging and operating temperature. Check new batteries every few weeks to determine the watering frequency for your application. It is normal for batteries to need more watering as they age. î î î î Use only distilled or deionized water. Tap water can contain contaminants that will damage the battery.
TABLE 3 WATER IM PU RITY LIM ITS Impurity Color Parts Per M illion Eff ects of 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 0.5 Self-discharge, can form poisonous gas at negative plate Calcium 40 Increase of positive plate shedding Chloride 5.
4 .3. CLEAN IN G 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. î î î î î î î 5 Disconnect the battery from the charging source and the load. Check that all vent caps are secured properly on the battery. Wipe off any accumulation of dust from the cell covers with a cloth dampened with clean water.
î î î î î Charging time will vary depending on battery size, charging device output, and depth of discharge. Lead-acid batteries do not have a memory effect and should not be fully discharged prior to charging. Do not discharge your battery more than 80%. This safety factor will eliminate the chance of over-discharging and damaging your battery. Renewable energy applications are typically designed for a 20% - 50% depth of discharge.
TABLE 4 FLO O D ED / WET BATTERIES - N O RM AL CH ARGIN G PARAM ETERS @ 25°C ( 77°F) Trojan Battery Line Maximum Charge Current* (% of C 20) Absorption Voltage** (V/cell) Maximum Current Absorption Phase Finish (% of C 20) Time (hours) Equalization Voltage (V/cell) Float Voltage (V/cell) Temperature Compensation (V/cell) Fahrenheit: -2.8 mV x (Tbattery -77) Solar Premium and Signature 13% 2.40 4 1-3% 2.70 2.
5.3. EQ UALIZIN G î When batteries are used in a battery bank, over time some of the batteries can drift to a lower state of charge than others. This charge imbalance can lead to sulfation and premature battery failure. To correct these charge imbalances a process called “equalization” is used. Equalizing is an overcharge at the voltage specified in Table 4 and is performed after fully charging deep-cycle flooded/wet batteries.
6 STORAGE The following tips will help ensure that your batteries emerge from storage in good condition: î Charge batteries before placing them in storage. î Store in a cool and dry location, protected from the elements. î Disconnect from equipment to eliminate potential parasitic loads that may discharge the batteries. î Batteries gradually self-discharge during transit and storage, so monitor the specific gravity or open-circuit voltage every 4 - 6 weeks.
6.2. STO RAGE IN CO LD EN V IRO N M EN TS Freezing Point of Electrolyte If possible, avoid locations where freezing temperatures are expected during storage. Batteries can freeze in cold Temperature Specific Gravity temperatures (less than 32°F or 0°C) if they are not fully °C °F charged. If batteries are stored during cold winter months, 1.280 -68.9 -92.0 it is critical that they be kept at a high state of charge as 1.265 -57.4 -71.3 outlined above. 1.250 -52.2 -62.0 1.200 -26.7 -16.
8 WHAT TO EXPECT FROM YOUR TROJAN BATTERY î î î î î 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. Trojan’s deep-cycle flooded batteries take 50 - 100 cycles to achieve full, peak capacity. When operating batteries at temperatures below 80°F (27°C), they will deliver less than the rated 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.
TABLE 7 O N - CH ARGE TEST TH RESH O LD S N O M I N AL BATTERY VO LTAGE M I N I M U M VO LTAGE TH RESH O LD ALLO WABLE VARI ATI O N WI TH I N A SET 2V 2.33V 0.33V 4V 4.66V 0.47V 6V 7.00V 0.7V 9.3. SPECIFI C GRAV ITY ( FLO O D ED / WET BATTERIES O N LY) A specific gravity reading is the most accurate way to determine a battery’s state of charge. This measurement is based on the density of the electrolyte compared to the density of water and is typically determined by the use of a hydrometer.
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 A Ampere °F Degrees Fahrenheit Ah Ampere-hour IN D Industrial Terminal AWG American Wire Gauge SO C State of Charge °C Degrees Celsius V Volt DOD Depth of Discharge 28 T R O J A N B A T T E R Y
N otes U S E R ’ S G U I D E 29
N otes 30 T R O J A N B A T T E R Y
N otes 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. TR O JA N B A T TE R Y C O M PA N Y 12380 Clark Street, Santa Fe Springs, CA 90670 USA Ca ll 8 0 0 - 4 2 3 - 6 5 6 9 E x t . 3 0 4 5 o r +1- 5 6 2-2 3 6 - 3 0 4 5 o r vis it w w w.t r oj a n b a t t e r y.
