Trojan Flooded, AGM, Gel User Manual

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Page 1

USER’S GUIDE

Page 2

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. From the

T2 Technology™ in our ooded batteries to the C-Max Technology™ in the

Reliant™ AGM line, our goal is to provide clean and reliable energy storage

solutions that enhance the way people live and work around the world.

Page 3

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.

800-423-6569 Ext. 3045 / +1-562-236-3045

TECHNICAL SUPPORT

Page 4

Contents

01 Safety . . . . . . . . . . . . . . . . . . 5

02 Equipment Needed. . . . . . . . . . . . 5

03 Battery Installation . . . . . . . . . . . 6

3.1 Battery Connections . . . . . . . . . . . . . 6

3.2Terminal Types . . . . . . . . . . . . . . . 6

3.4Cable Size . . . . . . . . . . . . . . . . .10

3.5Torque Values . . . . . . . . . . . . . . . .11

3.6Terminal Protection . . . . . . . . . . . . .12

3.7Connecting Batteries to Increase System Power . . .12

3.8Ventilation . . . . . . . . . . . . . . . . .13

3.9Battery Orientation. . . . . . . . . . . . . .13

3.10Battery Environment . . . . . . . . . . . .13

3.11Temperature. . . . . . . . . . . . . . . . 13

04 Preventative Maintenance . . . . . . . . 14

4.1Inspection . . . . . . . . . . . . . . . . .14

4.2Watering . . . . . . . . . . . . . . . . . 14

4.3Cleaning. . . . . . . . . . . . . . . . . .16

4.4Charging & Equalizing. . . . . . . . . . . . .16

4.4.1Boost Charging . . . . . . . . . . . . . .16

4.4.2Charging . . . . . . . . . . . . . . . .18

4.4.3Equalizing . . . . . . . . . . . . . . . .22

05 Storage . . . . . . . . . . . . . . . . . 24

5.1 Storage in Hot Environments . . . . . . . . . .24

5.2Storage in Cold Environments . . . . . . . . .24

06 How to Maximize the Performance of your

Trojan Battery . . . . . . . . . . . . . . 24

07 What to Expect from your Trojan Battery . 25

08 Trouble-Shooting. . . . . . . . . . . . . 26

8.1Preparation for Testing . . . . . . . . . . . .26

8.2On-Charge Voltage Testing . . . . . . . . . . .26

8.3Specic Gravity . . . . . . . . . . . . . . .27

8.4Open Circuit Voltage Testing . . . . . . . . . .27

8.5Discharge Testing . . . . . . . . . . . . . .28

09 Battery Recycling . . . . . . . . . . . . 29

10 Battery Acronyms . . . . . . . . . . . . 30

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USER’S GUIDE

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.

Always Never

Always wear protective clothes, gloves & safety goggles Never smoke near batteries

Always use insulated tools when working on batteries Never wear jewelry or other metal objects when working on

or around batteries

Always check connections for proper torque Never make direct contact with the electrolyte (sulfuric acid). If this occurs,

ush with large amounts of water.

Always charge batteries in well-ventilated areas Never place objects on top of batteries, which can cause a short circuit

Always keep sparks and ames* away from batteries Never add acid to a battery

Always use largest cable size of shortest length to minimize voltage drop Never charge a frozen battery

Always ensure plates are covered in water before charging Never charge a ooded battery without securing vent caps on the cells

Always make sure charger is set for the appropriate battery type (ooded, AGM or gel)

Never charge a battery when the temperature is above 122° F (50°C)

Always charge batteries before installing Never store batteries unless they are fully charged

Always neutralize acid spills with baking soda and water Never leave an acid spill unattended

WARNING Risk of re, explosion, or burns. Do not disassemble, heat above 70° C (160° F),

or incinerate.

02 Equipment Needed

Before installation or maintenance of your batteries, have the following equipment available:

î Proper personal protective equipment

(eye protection and acid resistant gloves)

î Distilled or treated water (deionized or

reverse osmosis)

î Insulated wrench

î Baking soda

î Terminal protector spray

î Voltmeter

î Hydrometer (deep-cycle

ooded/wet batteries)

î Discharge tester (if available)

î Battery charger

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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 re. To ensure proper connections, please use the following guidelines for cable size, torque values and terminal protection.

3.2 Terminal Types

Below are the various terminal types found on Trojan batteries. Refer to the appropriate terminal type

when determining proper torque in Section 3.5 below.

1 ELPT 2 EHPT 3 EAPT 4 EUT 5 LT 6 DT 7 UT

Embedded Low

Prole

Embedded High

Prole

Embedded Auto

Post

Embedded

Universal

L-Terminal Automotive Post

& Stud

Universal

8 AP 9 WNT 10 DWNT 11 ST 14 IND 15 M6/M8 15

Automotive Post Wingnut Dual Wingnut Stud Industrial

6mm/8mm Insert

3.3 Correct Hardware* Installation

If using at washers, it is very important to ensure the battery cable lug connection is contacting the lead

surface of the terminal, and the washer is placed on top of the wire connection. Do not place washer

between the battery terminal and the battery wire, which creates high resistance and can cause

terminal meltdown. It is important that fasteners be tightened to the appropriate torque for each

terminal type, as dened in Table 2.

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USER’S GUIDE

Flooded

ELPT EUT

EHPT EAPT

DT LT

IND

Images shown reect correct hardware placement. *Hardware not supplied by Trojan Battery Company.

Nut - Torque to 95 -105 in -lbs (11-12 Nm)

Washer*

AP Connector

Torque to 5 0-70 in-lbs (6 -8 Nm)

Cable Lug

Terminal

Stud Portion

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 Bolt Terminal

Cable Lug Nut - Torque to 10 0-120 in-lbs (11-14 Nm)

Washer* Bolt Terminal

Terminal

AP Connector

Torque to 5 0-70 in-lbs (6 -8 Nm)

Cable Lug Nut - Torque to 95 -105 in -lbs (11-12 Nm)

Washer* AP Terminal

AP Connector

Torque to 5 0-70 in-lbs (6 -8 Nm)

Stud Terminal

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AGM

LT DT

M6 M8

AP (RELIANT) AP

Images shown reect correct hardware placement. All hardware supplied for Reliant AGM. Hardware for non Reliant AGM is optional.

Nut - Torque to 55-70 i n-lbs (6-8 Nm) Nut - Torque to 95 -105 in -lbs (11-12 Nm) Washer Cable LugLock Washer Cable Lug Lock Washer Bolt - 20 mm AP Terminal M8 Terminal

AP Connector

Torque to 5 0-70 in-lbs (6 -8 Nm)

Bolt - 16mm - Torque t o 85-95 in-l bs (10-11 Nm)

Washer

Lock Washer

Stud Terminal

AP Connector

Torque to 5 0-70 in-lbs (6 -8 Nm)

Lock Washer Bolt - Torque to 85 -95 in-lbs (10 -11 Nm)

Washer Cable Lug Terminal

Lock Washer Bolt - Torque to 2 5-35 in-lbs (3- 4 Nm) Washer

Cable Lug Terminal

LT Adapter

AP Adapter

Torque to 8 5-95 in-lbs (10 -11 Nm)

M8 Terminal

Nut

- Torque to 120 -180 i n-lbs (14-20 Nm)

Cable Lug

Terminal

AP Connector

Torque to 4 4-62 in- lbs (5-7 Nm)

Terminal

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USER’S GUIDE

Gel

LT UT

DT AP

Images shown reect correct hardware placement. *Hardware not supplied by Trojan Battery Company.

Washer*

Nut - Torq ue to 95-105 in -lbs (11-12 Nm)

Cable Lug

Terminal

Washer*

Cable Lug

Terminal

AP Connector

Torque to 5 0-70 in-lbs (6 -8 Nm)

Terminal

Bolt

AP Connector

Torque to 5 0-70 in-lbs (6 -8 Nm)

Stud Terminal

AP Terminal

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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

Cable/Wire Gauge Size (AWG) Ampacity (amps)

14 25

12 30

10 40

8 55

6 75

4 95

2 130

1 150

1/0 170

2/0 265

4/0 360

Table values are for cable lengths

less than 6 feet (1829 mm). In

series/parallel battery banks, it

is preferable for all series cables

to be the same length, and all

parallel cables to be the same

length.

For more information refer to the

National Electric Code for correct

cable/wire size, which can be

located at www.nfpa.org.

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USER’S GUIDE

3.5 Torque Values

Tighten all cable connections to the proper specication 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 re. Refer to Table 2 for the proper torque values based on the type of

terminal on your battery.

Table 2

Terminal Type Dry Torque (in-lb) Dry Torque (Nm)

Flooded

DWNT, ELPT, EUT, LT, UT, WNT 95 - 105 11 - 12

EAPT, AP 50 - 70 6 - 8

DT, EHPT

50 - 70 (AP Connector)

95 - 105 (Stud Portion)

6 - 8 (AP Connector)

11-12 (Stud Portion)

IND 100 - 120 11 - 14

AGM

M8 85 - 95 10 - 11

AP (Adapter) Reliant

50 - 70 (AP Connector)

95 - 105 (AP Adapter)

6 - 7 (AP Connector)

11 - 12 (AP Adapter)

AP 44 - 62 5 - 7

50 - 70 (AP Connector)

95 - 105 (Stud Portion)

6 - 8 (AP Connector)

11-12 (Stud Portion)

LT (Adapter)

55 - 70 (Nut)

85 - 95 (Bolt)

6 - 8 (Nut)

10 - 11 (Bolt)

M6 25 -35 3 - 4

ST 120 - 180 14 - 20

Gel

AP 50 - 70 6 - 8

LT, UT 95 - 105 11 - 12

50 - 70 (AP Connector)

95 - 105 (Stud Portion)

6 - 8 (AP Connector)

11-12 (Stud Portion)

WARNING

Use an insulated wrench when making battery connections.

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TROJAN 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 conguring your batteries as follows:

Series Connect Parallel Connect Series/Parallel Connect

Note: maximum of three parallel strings

To increase voltage, connect batteries in series. This will not increase the system capacit y.

To increase capacity, connect batteries in parallel. This will not increase the system voltage.

To increase both voltage and capacity, connect additional batteries in series and parallel.

EXAMPLE

Two T-105, 6V Batteries rated at 225AH Connected in Series

Two T-105, 6V Batteries rated at 225AH Connected in Parallel

Four T-105, 6V Batteries rated at 225A Connected in Series/Parallel

Voltage 6V + 6V = 12V System Capacity = 225AH

Voltage 6V System Capacity = 225AH + 225AH = 450AH

Voltage 6V + 6V = 12V System Capacity = 225AH + 225AH = 450AH

Call Tech Support for Additional Congurations

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USER’S GUIDE

3.8 Ventilation

Deep-cycle ooded/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 ooded 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.

3.9 Battery Orientation

Deep-cycle ooded/wet batteries must be placed upright at all times. Fluid in the battery will spill if the

battery is placed on its side or at an angle. Deep-cycle AGM or gel batteries are non-spillable and can be

placed either upright or on their side.

3 .10 Battery Environment

Batteries should be stored and installed in a clean, cool and dry place, keeping water, oil, and dirt away

from the batteries. If any of these materials are allowed to accumulate on the batteries, tracking and

current leakage can occur, resulting in self-discharge and possible short-circuits. Battery chargers should

also be installed in well-ventilated, clean areas that are easily accessible.

3 .11 Temperature

The recommended operating temperature range is between -4°F to 122°F (-20°C to +50°C) with a

humidity of <90%. Elevated battery electrolyte temperatures of >80°F (27°C) will reduce operating life,

while lower battery electrolyte temperatures of <80°F (27°C) will reduce battery performance.

It is important to minimize temperature variations between the cells, therefore, do not arrange the

batteries where they are too tightly packed together which restricts airow. The batteries should have a

minimum of 0.50” (12.7 mm) of space between them to allow for adequate airow.

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04 Preventative Maintenance

4 .1 Inspection

î 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.

î If uids are present on the top of a deep-cycle ooded/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.

î If uid is present on the top of a deep-cycle AGM or gel battery, it may mean that the battery is being

overcharged, which can reduce battery performance and life.

î Check battery cables and connections. Replace any damaged cables and tighten any loose

connections. Refer to Torque Values Section 3.5.

4.2 Watering (ooded/wet batteries only)

Deep-cycle ooded/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.

Water should NEVER be added to deep-cycle AGM or gel batteries.

î Use only distilled or deionized water. Tap water can contain contaminants

that will damage the battery.

î Fully charge the batteries prior to adding water. Only add water to

discharged or partially charged batteries if the plates are exposed. In this case, add just enough water to cover the plates and then charge the batteries. Once completed, continue with the watering procedure below.

î Check the electrolyte levels by removing the vent caps and placing them upside down so that dirt

does not accumulate on the underside of the cap. For Plus Series™ batteries, simply ip open the cap.

î If the electrolyte level is well above the plates, then it is not necessary to add more water.

î If the electrolyte level is barely covering the plates, add distilled or de-ionized water to a level of

1/8” (3 mm) below the vent well. See right.

î After adding water, secure vent caps back onto batteries.

î If tap water is used, it must be tested to ensure that impurities are within acceptable limits. Refer to

Table 3 for Water Impurity Limits.

Standard Batteries

Plus Series™ batteries

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USER’S GUIDE

Table 3

Recommended Maximum Allowable Impurities in Water for Battery Use

Impurity Parts Per Million Eects 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 0.5 Self-discharge, can form poisonous gas at negative plate

Calcium 40 Increase of positive plate shedding

Chloride 5.0 Loss of capacity in both plates, greater loss on the positive plate

Copper 5.0 Increased self-discharge, lower on-charge voltage

Iron 3.0 Increased self-discharge at both plates, lower on-charge voltage

Magnesium 40 Reduced life

Nickel None Allowed Intense lowering of on-charge voltage

Nitrates 10 Increased sulfation on the negative plate

Nitrites 5.0 Corrosion of both plates, loss of capacity, reduced life

Platinum None Allowed Increased self-discharge, lower on-charge voltage

Selenium 2.0 Positive plate shedding

Zinc 4.0 Slight self-discharge of negative plate

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4.3 Cleaning

Check the battery for cleanliness at regular intervals and keep terminals and connectors free of corrosion.

Terminal corrosion may adversely aect the performance of the battery and present a safety hazard.

î 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). Do not allow cleaning solution to get inside the battery.

î Rinse with water and dry with a clean cloth.

î Apply a thin coat of terminal protector spray that can be purchased through your local battery dealer.

î Keep the area around batteries clean and dry.

4.4 Charging & Equalizing

4.4.1 Boost Charging

The term boost charging refers to fully charging your batteries before they are used or when they are in

storage.

Flooded Batteries

Two methods can be used to boost charge ooded batteries, either automatically or manually. If using the automatic method (charger is preprogrammed), simply allow the charger to go through the complete charge cycle.

If you use the manual method (charger has adjustable settings) follow the steps below:

î Boost charge at CONSTANT CURRENT, without voltage limit, at 3% of C until the voltage stops

increasing for three consecutive hourly readings. If using CONSTANT VOLTAGE, the recommended boost charge voltage is 2.45  2.58 V/cell with the charger output current limited to 3 - 5% of C. Using voltages at the lower end of this range will result in an extended boost time.

î The boost charge is not complete until the specic gravity readings of each cell remain constant over

three successive hourly readings and all cells are gassing freely. If you have questions concerning boost charging, contact Trojan Battery Company Technical Support.

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USER’S GUIDE

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:

î Boost charge at a CONSTANT VOLTAGE of (2.40 V/cell) with the current limited to 20% of C.

Example: 20 amps for a battery with a C of 100Ah.

î The time needed to boost charge the cells can be determined using the equation below.

Depth of discharge (DOD) can be determined using the information in Table 7.

Boost Charge Time in Hours =

+ 5 Hours

DOD X Capacity at 20Hr Rate

Maximum Charge Current

For example, a 100Ah battery taken down to a 25% depth of discharge (DOD) or 75% state of charge

(SOC) will need to be boost charged for 7½ hours with a 10A charger, or for 6¼ hours with a 20A charger.

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TROJAN BATTERY

4.4.2 Charging

Proper charging is imperative to maximize battery performance. Both under- or over-charging batteries

can signicantly 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.

î Batteries should be fully charged after each use. “Use” is dened as at least 30 minutes

of runtime.

î Deep-cycle ooded/wet charging guidelines: Refer to Table 4 and Diagram 4.

î Deep-cycle AGM charging guidelines: There are various ways to charge AGM batteries. For

optimum performance and life, Trojan recommends a 3-step prole as shown in Diagram 5 and following the guidelines in Table 5.

î Deep-cycle gel charging guidelines: Refer to Table 6 and Diagram 6.

î Before charging, make sure the charger is set to the appropriate program for deep-cycle ooded/wet,

AGM or gel, depending on the type of battery you are charging.

î Lead acid batteries (deep-cycle ooded/wet, AGM or gel) do not have a memory eect and therefore

do not need to be fully discharged before recharging.

î Charge only in well-ventilated areas.

î Check electrolyte levels in deep-cycle ooded/wet batteries to make sure plates are covered with

water before charging. Refer to Section 4.2.

î Check that all vent caps are secured properly on the battery before charging.

î Deep-cycle ooded/wet batteries will gas (bubble) towards the end of charge to ensure proper

mixing of the electrolyte.

î Never charge a frozen battery.

î Avoid charging at temperatures above 122°F (50°C).

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USER’S GUIDE

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

Bulk Charge (2.47 VPC) 7.41 9.88 14.82 29.64 44.46 59.28

Absorption Charge (2.35 – 2.45 VPC) 7.0 5 – 7.35 9.40 – 9.80 14.10 – 14.70 28.20 – 29.40 42.30 – 44.10 56.40 – 58.80

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

The chart below illustrates a typical recharge prole:

Diagram 4

Recommended Deep-Cycle Flooded/Wet Charging Prole

Voltage

(per cell)

Current

(Amps)

2.45V to 2.70V

(@25°C, 77°F)

2.35V to 2.45V

(@25°C, 77°F)

20% 90% 100%

State of Charge (%)

1-3% C

10-13% C

Charge Current

Charge Voltage

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TROJAN BATTERY

Table 5

Deep-Cycle AGM 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 57.6 0

Absorption Charge (2.35 – 2.45 VPC) 7.0 5 – 7.35 9.40 – 9.80 14.10 – 14.70 28.20 – 29.40 42.30 – 44.10 56.40 – 58.80

Finish Charge (2.45 VPC) 7.35 9.80 14.70 29.40 4 4.10 58.80

Float Charge (2.25 – 2.3 VPC) 6.75 9.00 13.50 27.00 40.50 54.00

** AGM 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 0.005 volt per cell for every 1°C below 25°C. Subtract 0.0028 volt per cell for every 1°F above 77°F, or add 0.0028 volt per cell for every 1°F below 77°F.

The chart below illustrates a typical recharge prole:

Diagram 5

Recommended Trojan Deep-Cycle AGM Charging Prole

Note: Charging time will vary depending on battery size, charger output, and depth of discharge.

Voltage

(per cell)

Current

(Amps)

2.35V to 2.45V

(@25°C, 77°F)

Charge Current

Charge Voltage

20% 80%

100%

State of Charge (%)

Approximately

C20/200

Will increase with age

20% C

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USER’S GUIDE

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 57.6 0

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

The chart below illustrates a typical recharge prole:

Diagram 6

Recommended Trojan Deep-Cycle Gel Charging Prole

Note: Charging time will vary depending on battery size, charger output, and depth of discharge.

Voltage

(per cell)

Current

(Amps)

2.40V

(@25°C, 77°F)

Charge Current

Charge Voltage

20% 80%

100%

State of Charge (%)

10-13% C

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TROJAN BATTERY

4.4.3 Equalizing (deep-cycle ooded/wet batteries only)

Equalizing is an overcharge performed after fully charging deep-cycle ooded/wet batteries. An

equalizing charge prevents battery stratication and reduces sulfation which are leading causes of

battery failure. Trojan recommends equalizing every 30 days or when batteries have a low specic

gravity reading after fully charging, below 1.235, or have a wide ranging specic gravity of >0.030 points

between cells. Reference Section 8.3 for instructions on specic gravity measurement.

Deep-cycle AGM or gel batteries should NEVER be equalized.

Equalization can be performed either automatically (as programmed on the charger) or by following the

procedure below:

î Check the battery’s electrolyte level in each cell to make sure the plates are covered before charging.

î Check that all vent caps are secured properly on the battery before charging.

î Set charger to equalizing mode.

î The batteries will gas (bubble) during the equalization process.

î Measure the specic gravity every hour. Refer to Table 7 for specic gravity and voltage

measurements. Discontinue the equalization charge when the specic gravity no longer rises.

WARNING Do not equalize deep-cycle AGM or gel batteries.

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USER’S GUIDE

Table 7

Flooded/Wet State of Charge as a Measure of Specic Gravity and Open-Circuit Voltage

Percentage Charge Specic Gravity Cell 6 Volt 8 Volt 12 Volt

100 1.277 2.12 2 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 1.14 8 1.993 5.98 7.97 11.96

30 1.124 1.969 5.91 7.8 8 11.81

20 1.098 1.943 5.83 7.7 7 11.66

10 1.073 1.918 5.75 7.67 11.51

AGM State of Charge as a Measure of Open-Circuit Voltage

Percentage Charge Specic Gravity Cell 6 Volt 8 Volt 12 Volt

100 NA 2.14 6.42 8.56 12.84

75 NA 2.09 6.27 8.36 12.54

50 NA 2.04 6.12 8.16 12.24

25 NA 1.99 5.97 7.9 6 11.94

0 NA 1.94 5.82 7.76 11.64

Gel State of Charge as a Measure of Open-Circuit Voltage

Percentage Charge Specic Gravity Cell 6 Volt 8 Volt 12 Volt

100 NA 2.14 6.42 8.56 12.84

75 NA 2 .11 6.33 8.44 12.66

50 NA 2.06 6.18 8.24 12.36

25 NA 2.00 6.00 8.00 12.00

0 NA 1.97 5.91 7.8 8 11.82

Page 24

TROJAN BATTERY

05 Storage

î Charge batteries before placing in storage.

î Store in a cool, dry location, protected from the elements.

î Disconnect from equipment to eliminate potential parasitic loads that

may discharge the battery.

î Batteries gradually self-discharge during transit and storage, so

monitor the specic gravity or voltage in ooded batteries every 4 - 6 weeks. Monitor the open circuit voltage for AGM or gel batteries every 2 - 3 months.

î Batteries in storage should be given a boost charge when they are at

70% SOC for ooded and 75% for AGM or gel. Refer to Table 7 for specic gravity (ooded only) and voltage measurements for ooded batteries and AGM or gel batteries. If boosting is needed, refer to Section 4.4.1 for boosting instructions.

î When batteries are taken out of storage, recharge before use.

5 .1 Storage in Hot Environments (greater than 90°F or 32°C)

Avoid direct exposure to heat sources, if possible, during storage. Batteries self-discharge faster in

high temperatures. If batteries are stored during hot summer months, monitor the specic gravity or

voltage more frequently (approximately every 2 - 4 weeks).

5.2 Storage in Cold Environments (less than 32°F or 0°C)

Avoid locations where freezing temperatures are expected, if possible, during storage. Batteries can

freeze in cold temperatures if they are not fully charged. If batteries are stored during cold winter

months, it is critical that they are kept fully charged at all times.

06 How to Maximize the Performance of your

Trojan Battery

î Follow all the procedures in this User’s Guide for proper installation, maintenance and storage.

î Do not discharge your battery more than 80%. This safety factor will eliminate the chance of over-

discharging and damaging your battery.

î 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.

Page 25

USER’S GUIDE

07 What to Expect from your Trojan Battery

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 maximum performance or peak capacity.

î Trojan’s deep-cycle AGM and gel batteries will reach rated capacity in less than 10 cycles.

î Trojan’s deep-cycle ooded batteries take between 50 – 100 cycles to achieve full, peak capacity.

î When operating batteries at temperatures below 80°F (27°C), they will deliver less than the rated

capacity. For example at 0°F (-18°C) the battery will deliver 50% of its capacity and at 80°F (27°C) it will deliver 100% of its capacity.

î When operating batteries at temperatures above 80°F (27°C), they will deliver more than the rated

capacity but battery life will be reduced.

î The life of a battery is dicult to predict and will vary by application, frequency of usage and

level of maintenance.

Capacity vs. Temperature

20%0% 40% 60% 80% 100% 120%

-20

-40

100

120

140

-20

-10

-30

-40

Percent of Available Capacity

Temperature (F)

Temperature (C)

Note: Typical behavior at 5-H r rate.

Page 26

TROJAN BATTERY

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 identied 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 the test data.

8 .1 Preparation for Testing

î 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). 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.

8.2 On-Charge Voltage Testing

î Disconnect and reconnect DC plug to restart charger.

î While the batteries are on-charge, record the current in the last ½ hour of 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

following readings, proceed to the next step:

î 56V for a 48V system

î 42V for a 36V system

î 28V for a 24V system

î 14V for a 12V battery

î 9.3V for a 8V battery or 7V for a 6V battery

î If the current at the end of the charge does not match these readings, 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 If any battery voltage is below 7V for 6V battery, 9.3V for 8V battery and 14V for 12V battery, and a

voltage variation is greater than 0.5V for 6V battery or 1.0V for a 12V battery, from any other battery in set, it may be a failed battery.

Page 27

USER’S GUIDE

8.3 Specific Gravity (flooded/wet batteries only)

î Fill and drain the hydrometer 2 - 3 times before drawing a sample from the battery.

î Measure specic gravity readings for all battery cells.

î Correct specic 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).

î If every cell in the battery set is below 1.235, the batteries may be undercharged and require

recharging.

î If any battery has a specic gravity variation of more than 0.030 between cells, equalize the set.

î If there is still a variation there may be a failed battery.

8.4 Open Circuit Voltage Testing

This is the least preferred method of evaluating the condition of a deep-cycle ooded/wet battery, but is

the only method for AGM and gel batteries.

î For accurate voltage readings, batteries must remain idle at least 6 hours, preferably up to 24 hours.

î Measure the individual battery voltages.

î If any battery voltage is greater than 0.3V compared to other batteries in set, equalize the set (deep-

cycle ooded/wet batteries ONLY). Refer to Equalizing Section 4.4.3.

î Measure the individual battery voltages again.

î If any battery voltage is still greater than 0.3V compared to any other battery in the set, you may have

a failed battery.

Page 28

TROJAN BATTERY

8.5 Discharge Testing

î Follow the procedure below to determine battery capacity.

î Connect and start discharger.

î Record the runtime (minutes) when discharge is complete.

î Correct runtime minutes for temperature using the following formula (valid between 75°F (24°C)

and 90°F (32°C):

= Mr [1 – 0.005* (T1 - 80*)] *(For Celsius, use 0.009 & 27°C)

Where M

= Discharge time corrected to 80°F (or 27°C)

= Actual discharge time

= Battery temperature at end of discharge (°F or °C)

î If the discharge runtime is greater than 50% of the batteries’ rated capacity at that discharge rate, then

all the batteries are operational.

î Restart the discharger to record the individual battery voltages while still under load

(current being drawn).

î If the discharge runtime is less than 50% of the batteries’ rated capacity, the battery with a voltage

that is 0.5V lower than the highest voltage may be a failed battery.

There are other methods of testing batteries including internal resistance (i.e. C.C.A. testers) and carbon

pile discharge testers. However these are not suitable testing methods for deep-cycle batteries.

Page 29

USER’S GUIDE

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.

Below is the process in which your Trojan battery will be recycled:

Recycling For A Better Environment

Transportation

The same network that distributes new batteries also safely collects and returns used batteries for recycling

At the recycling facility, used batteries are broken apart and separated into components to begin the recycling process

Plastic

Plastic pellets recycled from battery cases and covers are used to manufacture new cases and covers

Lead

Lead ingots recycled from battery grids, other battery parts (e.g., posts and terminals) and lead-oxide are used to manufacture lead for new grids, parts, and lead oxide

Electrolyte:

Option 1

Sodium sulfate crystals separated from used electrolyte (dilute sulfuric acid) is recycled and sold for use in textiles, glass and detergent manufacturing

Electrolyte:

Option 2

At some recyclers, used electrolyte is reclaimed and reused in manufacturing new batteries. At others, it is neutralized and managed according to federal and state water permits

New Battery

New Grids and Lead Oxide

New battery grids are manufactured from recycled lead. Recovered lead oxide is also used in new battery manufacturing

Crush the case and covers

Plastic pellets

New Covers and Cases

New battery covers and cases are manufactured using recycled plastic pellets

New cases and covers

Lead Oxide

New grids

Lead ingots

Melt grids

Neutralize electrolyte

Electrolyte is chemically treated and reused

Electrolyte is neutralized and sent to a water treatment plant

Sodium sulfate crystals

Glass, textiles, detergent

Graphics provided by Battery Council International

Page 30

TROJAN BATTERY

AGM Absorbed Glass Mat

AMP Ampere

AH Amp-Hours

AWG American Wire Gauge

AP Automotive Post Terminal

°C Degrees Celsius

C.C.A. Cold Cranking Amps

DOD Depth of Discharge

DT Automotive Post & Stud Terminal

DWNT Dual Wingnut Terminal

EAPT Embedded Automotive Post Terminal

EHPT Embedded High Prole Terminal

ELPT Embedded Low Prole Terminal

EUT Embedded Universal Terminal °F Degrees Fahrenheit

IND Industrial Terminal

LT L-Terminal

M6/M8 6mm - 8mm Teminal

Mc Corrected Minutes

Mr Minutes Recorded

SOC State of Charge

ST Stud Terminal

T Temperature

UT Universal Terminal

V Volt

WNT Wingnut Terminal

10 Battery Acronyms

Notes

Page 31

USER’S GUIDE

Trojan Battery Company

TROJAN BATTERY COMPANY

12380 Clark Street, Santa Fe Springs, CA 90670 USA

Call 800-423-6569 Ext. 3045 or +1-562-236-3045

or Visit www.trojanbattery.com

This publication is protec ted by copyright and all rights are reserved. No part of it may be reproduced or transmitted by any means or in any form, without prior consent in writing from Trojan Battery Company.

Trojan Batter y Company is not liable for direct, indirec t, special, exemplar y, incidental or consequential damages that may result from any information provided in or omitted from this manual, under any circumstances.

Trojan Batter y Company reser ves the right to make adjustments to this manual at any time, without notices or obligation.

Trojan Batter y Company and the Trojan Batter y logo are registered trademarks of Trojan Batter y Company.

T2 Technology, C-Max Technology, Reliant AGM, and Plus Series are trademarks of Trojan Battery Company in the United States and other countries.

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.

Page 32

TRJ-N0109_Users Guide EN 2016_0822

Trojan batteries are available worldwide through Trojan’s Master Distributor Network. We oer outstanding technical support, provided by full-time application engineers.

© 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. Trojan Battery Company reserves the right to make adjustments to this publication at any time, without notice or obligation. Please check the Trojan Battery website (www.trojanbattery.com) for the most up-to-date information.

trojanbattery.com

800.423.6569 or + 1.562.236.3000

12380 Clark Street, Santa Fe Springs, CA 90670 • USA