U S E R ` S G U I D E - Trojan Battery Company
Contents
1. AP RELIANT AP AP Connector Torque to 50 70 in lbs 6 8 Nm AP Adapter Torque to 85 95 in lbs 10 11 Nm M8 Terminal AP Connector Torque to 44 62 in lbs 5 7 Nm Terminal Images shown reflect correct hardware placement All hardware supplied for Reliant AGM Hardware for non Reliant AGM is optional 8 ro 34 D MS E O LT Nut Torque to 95 105 in Ibs 11 12 Nm Cable Lug x Washer Wane l Terminal Nut Torque to 95 105 in Ibs 11 12 Nm Bolt Terminal Cable Lug Bolt DT AP Nut Torque to 95 105 in Ibs 11 12 Nm Cable Lug Washer AP Connector Torque to 50 70 in Ibs 6 8 Nm AP Terminal Terminal AP Connector Torque to 50 70 in Ibs 6 8 Nm Stud Terminal Images shown reflect correct hardware placement Hardware not supplied by Trojan Battery Company IES RE es 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 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 10 TI D MS O ey 3 5 Torque V2. 13 3 10 Battery Environment 13 3 11 Temperature FEE e 13 Preventative Maintenance 14 A inspection RC S 14 4 2 Watering o ce ecg S C 14 4 3 leaning ete S 16 4 4 Charging 8 Equalizing 16 4 4 1 Boost Charging 16 4 4 2 Charging 7 ve 18 4 4 3 tqualizing 2 649 a a 22 Storage e e e e e e e e e e e e e e e e e 24 5 1 Storage in Hot Environments 24 5 2 Storage in Cold Environments OG 07 os 09 10 How to Maximize the Performance of your TrojanBattery 24 What to Expect from your Trojan Battery 25 Trouble Shooting 26 8 1 Preparation for Testing 26 8 2 On Charge Voltage Testing 26 8 3 Specific Gravity A e a a a 27 8 4 Open Circuit Voltage Testing 27 8 5 Discharge Testing 28 Battery Recycling 29 Battery Acronyms 30 O1 o2 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 amp safety goggles Never smoke near batteries Always use insulated tools when working on batteries Never wear jewelry or other metal objects when working
3. Distilled or treated water i e de ionized gt Hydrometer deep cycle flooded wet reverse OSMOSIS etc batteries gt Insulated wrench Discharge tester if available gt Baking soda Battery charger gt Terminal protector spray US ing oe OS 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 fire 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 ELPT 2 EHPT 3 EAPT EmbeddedLow Embedded High Embedded Auto Embedded L Terminal Automotive Post Universal Profile Profile Post Universal amp Stud 8 9 WNT 10 DWNT IND 15 M6 M8 Automotive Post Wingnut Dual Wingnut Industrial 6mm 8mm Insert 3 3 Correct Hardware Installation If using 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 terminal lead and the battery wire which create
4. a Irojan USER S GUIDE BATTERY COMPANY F Meharnt i hee i a i i F F 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 12 Technology in our flooded 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 This Users 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 lt will help you achieve optimum performance and long life from your new investment A TECHNICAL SUPPORT 800 423 6569 Ext 3045 1 562 236 3045 u Contents 01 o2 Os 04 OS Safety T VSK S Equipment Needed 5 Battery Installation 6 3 1 Battery Connections 6 3 2 lerminalilypes rn ae da 6 SA Cable Size ca A V K ee a 10 3 5 Torque Values 1 61 SENS 11 3 6 Terminal Protection 12 3 7 Connecting Batteries to Increase System Power 12 3 8 Ventilation oe C LV 13 3 9 Battery Orientation
5. 009 amp 27 C Where M_ Discharge time corrected to 80 F or 27 C M Actual discharge time T Battery temperature at end of discharge F or C gt Ifthe discharge runtime is greater than 50 of the batteries rated capacity at that discharge rate then all the batteries are operational gt Restart the discharger to record the individual battery voltage while still under load current being drawn gt Ifthe 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 AN D MS ue OS 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 ofthe 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 Transportation The same network that distributes new batteries also safely collects and returns used batteries for r
6. Trojan Battery Company Trojan Battery Company is not liable for direct indirect special exemplary incidental or consequential damages that may result from any information provided in or omitted from this manual under any circumstances Trojan Battery Company reserves the right to make adjustments to this manual at any time without notices or obligation Trojan Battery Company and the Trojan Battery logo are registered trademarks of Trojan Battery Company T2 Technology GMax Technology Reliant AGM and Plus Series are trademarks of Trojan Battery Company in the United States and other countries 4 as J Trojan batteries are available worldwide tr oj an b atter y com through Trojan s Master Distributor e Network We offer outstanding technical ss S SI BATTERY COMPANY support provided by full time 12380 Clark Street Santa Fe Springs CA 90670 USA application engineers Clean energy for life 2015 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 Please check the Trojan Battery website www trojanbattery com for the most up to date information Users Guide EN 2015_0812
7. add water if necessary Refer to Watering Section 4 2 Ensure batteries are fully charged before discharge testing to obtain accurate results 8 2 On Charge Voltage Testing p p Disconnect and reconnect DC plug to restart charger While the batteries are on charge record the current in the last Y hour of charge cycle if possible and measure the battery set voltage 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 gt 56Vfora 48V system gt 42V for a 36V system gt 28V for a 24V system gt 14V for a 12V battery gt 9 3V for a 8V battery or 7V for a 6V battery 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 While the batteries are on charge measure the individual battery voltages 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 AN BA 0 8 3 Specific Gravity flooded wet batteries only gt Fill and drain the hydrometer 2 3 times before drawing a sample from the battery gt Measure specific gravity readings for all battery cells gt Correct specific gravity readings for temper
8. on or around batteries Always check connections for proper torque Never make direct contact with the electrolyte sulfuric acid If this occurs flush 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 flames 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 flooded battery without securing vent caps on the cells Always make sure charger is set for the appropriate battery type flooded AGM or gel 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 fire explosion or burns Do not disassemble heat above 70 C 160 F or incinerate EXCEPTION This statement may be included in the instructions provided with the battery rather than be marked on the battery Never charge a battery when the temperature is above 122 F 50 C Equipment Needed Before installation or maintenance of your batteries have the following equipment available Proper personal protective equipment eye protection and acid resistant gloves gt Voltmeter deep cycle flooded wet AGM and gel batteries gt
9. operating batteries at temperatures above 80 27 C they will deliver more than the rated capacity but will reduce battery life gt The life of a battery is difficult to predict and will vary by application frequency of usage and level of maintenance Capacity vs Temperature 140 60 120 50 100 40 30 80 20 60 40 Temperature F Temperature C 20 20 20 30 40 0 20 40 60 80 100 120 Percent of Available Capacity OS 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 1 562 236 3045 for help interpreting the test data 8 1 Preparation for Testing p p Check that all vent caps are secured properly on the battery 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 Check battery cables and connections Replace any damaged cables Tighten any loose connections with an insulated wrench Refer to Torgue Values Section 3 5 For deep cycle flooded wet batteries check the electrolyte level and
10. alues 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 Table 2 Terminal Type Torque in Ib Torque Nm DWNT ELPT EUT LT UT WNT 105 EAPT AP 50 70 50 70 AP Connector 6 8 AP Connector DT EHPT 105 Stud Portion 11 12 Stud Portion 50 70 AP Connector 6 7 AP Connector AP Adapter Reliant 105 AP Adapter 11 12 AP Adapter 50 70 AP Connector 6 8 AP Connector 105 Stud Portion 11 12 Stud Portion 70 Nut 6 8 Nut 85 95 Bolt 10 11 Bolt 180 14 20 50 70 U 105 50 70 AP Connector 6 8 AP Connector 105 Stud Portion 11 12 Stud Portion WARNING Use an insulated wrench when making battery connections 3 6 Terminal Protection Corrosion can build up on terminals if they are not kept clean and dry To prevent corrosion 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 configuring your batteries as follows Parallel Connect Series Parallel Connect To increase voltage connect batteriesin To increase capacity connect batteri
11. ature 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 gt Ifevery cell in the battery set is below 1 235 the batteries may be undercharged and require recharging gt Ifany battery has a specific gravity variation of more than 0 030 between cells equalize the set gt 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 flooded wet battery but is the only method for AGM and gel batteries gt gt gt For accurate voltage readings batteries must remain idle at least 6 hours preferably up to 24 hours Measure the individual battery voltages If any battery voltage is greater than 0 3V compared to other batteries in set equalize the set deep cycle flooded wet batteries ONLY Refer to Equalizing Section 4 4 3 Measure the individual battery voltages again If any battery voltage is still greater than 0 3V compared to any other battery in the set you may have a failed battery 8 5 Discharge Testing Follow the procedure below to determine battery capacity Connect and start discharger Record the runtime minutes when discharge is complete v vo TF YH Correct runtime minutes for temperature using the following formula valid between 75 F 24 C and 90 F 32 C M M_ 1 0 005 T 80 For Celsius use 0
12. ay from the batteries If any of these materials are allowed to accumulate on the batteries tracking and voltage 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 lt 90 Elevated battery electrolyte temperatures of gt 80 F 27 C will reduce operating life while lower battery electrolyte temperatures of lt 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 airflow The batteries should have a minimum of 0 50 12 7 mm of space between them to allow for adequate airflow IES RE es 04 Preventative Maintenance 4 1 Inspection gt 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 gt 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 Watering Section 4 2 for the proper watering procedure gt Iffluid is present on the top of a deep cycle AGM or gel battery it may mean that the batter
13. d 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 OG How to Maximize the Performance of your Trojan Battery gt Follow all the procedures in this User s Guide for proper installation maintenance and storage gt Do not discharge your battery more than 80 This safety factor will eliminate the chance of over discharging and damaging your battery gt Ifyou have any questions or concerns about battery care please contact Trojan Battery PS Company s technical support engineers at 800 423 6569 Ext 3045 or 1 562 236 3045 before a problem develops O AA D MS E O O What to Expect from your Trojan Battery gt 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 gt Trojans deep cycle AGM and gel batteries will reach rated capacity in less than 10 cycles gt Trojans deep cycle flooded batteries take between 50 100 cycles to achieve full peak capacity gt When operating batteries at temperatures below 80 F 27 C they will deliver less than the rated capacity For example at 0 18 C the battery will deliver 50 of its capacity and at 80 F 27 C it will deliver 100 of its capacity gt When
14. ecycling Recycling For A Better Environment At the recycling facility used batteries are broken apart and separated into components to begin the recycling process A tw Plastic Plastic pellets recycled from battery cases and covers are used to manufacture new cases and covers Crush the case and covers aid ga NA Plastic pellets lt 2 New Covers and Cases New battery covers and cases are manufactured using recycled plastic pellets New cases and A wa Y 9 Ge 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 Melt grids Lead ingots New Grids and Lead Oxide New battery grids are manufactured from recycled lead Recovered lead oxide is also used in new battery manufacturing New grids Lead Oxide De Graphics provided by Battery Council International y te 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 Neutralize electrolyte si Sodium sulfate crystals Glass textiles detergent New Battery Ws E Un Y te Electrolyte Option 2 At some recyclers used electrolyte is reclaimed and reused in manufacturing new batteries At others it is neutralized and managed accord
15. ent 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 7 hours with a 10A charger or for 6 hours with a 20A charger 4 4 2 Charging Proper charging is imperative to maximize battery performance Both under or over charging batteries can significantly 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 gt Batteries should be fully charged after each use Use is defined of at least 30 minutes of runtime Deep cycle flooded wet charging guidelines Refer to Table 4 and Diagram 4 Deep cycle AGM charging guidelines There are various ways to charge AGM batteries For optimum performance and life Trojan recommends a 3 step profile as shown in Diagram 5 and following the guidelines in Table 5 Deep cycle gel charging guidelines Refer to Table 6 and Diagram 6 Before charging make sure the charger is set to the appropriate program for deep cycle flooded wet AGM or gel depending on the type of battery you are charging Lead acid batteries deep cycle flooded wet AGM or gel do not have a memory effect and therefore and do not need to be fully discharged before recharging Charge only in well ventilated areas Check electrolyte levels in deep cycle f
16. ery 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 profile Diagram 5 Recommended Trojan Deep Cycle AGM Charging Profile Voltage Current per cell kiju Charge Current EN senses acacia 20 C 2 35V to 2 45V 25 C 77 F Charge Voltage N Approximately C 200 Will increase m a TE with age State of Charge Note Charging time will vary depending on battery size charger output and depth of discharge 20 TI D MS O iy Table 6 Deep Cycle Gel Batteries Charger Voltage Settings 5 Float Charge ifdesired 2 25 VPC 6 75 90 B5 mM 405 ee 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 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 profile Diagram 6 Recommended Trojan Deep Cycle Gel Charging Profile Voltage Current Charge Current ad per cell Amps A aes 10 13 C 25 C 77 F Charge Voltage As 20 80 100 State of Charge Note Chargin
17. es To increase both voltage and capacity series This will not increase the system in parallel This will not increase the connect additional batteries in series capacity system voltage and parallel Two 1 105 6V Batteries rated at 225AH Two 1 105 6V Batteries rated at 225AH Four 105 6V Batteries rated at 225A Connected in Series Connected in Parallel Connected in Series Parallel Voltage 6V 6V 12V System Voltage 6V System Voltage 6V 6V 12V System Capacity 225AH Capacity 225AH 225AH 450AH Capacity 225AH 225AH 450AH Call Tech Support for Additional Configurations 12 BS D MS O ey 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 more assistance in determining ventilation needs please contact Trojan Battery Company s technical support engineers 3 9 Battery Orientation Deep cycle flooded 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 aw
18. g time will vary depending on battery size charger output and depth of discharge IE en es 4 4 3 Egualizing deep cycle flooded wet batteries only Egualizing is an overcharge performed after fully charging deep cycle flooded wet batteries An equalizing charge prevents battery stratification and reduces sulfation which are leading causes of battery failure Trojan recommends equalizing every 30 days or when batteries have a low specific gravity reading after fully charging below 1 235 or have a wide ranging specific gravity of gt 0 030 points between cells 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 Check the battery s electrolyte level in each cell to make sure the plates are covered before charging Check that all vent caps are secured properly on the battery before charging Set charger to equalizing mode The batteries will gas bubble during the equalization process v Vv vi YF V Measure the specific gravity every hour Refer to Table 7 for specific gravity and voltage measurements Discontinue the egualization charge when the specific gravity no longer rises WARNING Donotegualize deep cycle AGM or gel batteries AN D MS ue Table 7 Flooded Wet State of liks as a Measure of Specific Gravity and Open Circuit Voltage Ti 1 67 AGM State of Charge as a Measure of Open Circuit Volta
19. ge o a o e e Gel State of Charge as a Measure of Open Circuit Voltage w w m a s s AT oa M 7 IRE i a w w w a sa er T ee a Oo m w o S OS Storage p gt gt Charge batteries before placing in storage Store in a cool dry location protected from the elements Disconnect from equipment to eliminate potential parasitic loads that may discharge the battery Batteries gradually self discharge during transit and storage so monitor the specific gravity or voltage in flooded batteries every 4 6 weeks Monitor the open circuit voltage for AGM or gel batteries every 2 3 months Batteries in storage should be given a boost charge when they are at 70 SOC for flooded and 75 for AGM or gel Refer to Table 7 for specific gravity flooded only and voltage Measurements for flooded batteries and AGM or gel batteries If boosting is needed refer to Section 4 4 1 for boosting instructions 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 specific 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 expecte
20. ing to federal and state water permits Electrolyte Electrolyte is neutralized is chemically and sentto treated and a water reused treatment plant 1O AGM AMP AH AWG AP C C C A DT DWNT EAPT EHPT ELPT EUT Notes Battery Acronyms Absorbed Glass Mat Amperage Amp Hours American Wire Gauge Automotive Post Terminal Celsius Cold Cranking Amps Automotive Post amp Stud Terminal Dual Wingnut Terminal Embedded Automotive Post Terminal Embedded High Profile Terminal Embedded Low Profile Terminal Embedded Universal Terminal WNT Fahrenheit Industrial Terminal L Terminal 6mm 8mm Teminal Corrected Minutes Minutes Recorded State of Charge Stud Terminal Temperature Universal Terminal Volt Wingnut Terminal D MS E O 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 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 protected 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
21. looded wet batteries to make sure plates are covered with water before charging Refer to Section 4 2 Check that all vent caps are secured properly on the battery before charging Deep cycle flooded wet batteries will gas bubble towards the end of charge to ensure proper mixing of the electrolyte Never charge a frozen battery Avoid charging at temperatures above 122 F 50 C 18 TI Bede ey Table 4 Deep Cycle Flooded Wet Batteries Charger Voltage Settings 025 C 77 F Absorption Charge 2 35 2 45 VPC 14 1 Equalize Charge 2 70 VPC Float Charge if desired 2 25 VPC a BB T eaa The chart below illustrates a typical recharge profile E 155 Diagram 4 Recommended Deep Cycle Flooded Wet Charging Profile Voltage Current per cell Ch C g arge Current M as esaca 10 13 C DAS TG 27 OY sa ere as one ceases ssa ea 25 C 77 F f EE E E g AE 25 C 77 F f Charge Voltage a 1 3 C 20 90 100 State of Charge Note Charging time will vary depending on battery size charger output and depth of discharge Table 5 Deep Cycle AGM Batteries Charger Voltage Settings 144 Buk Charge 240 VPC E m as a mom Tu fatet atate Pagosa s w ws a as 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 ev
22. o batteries gt Tap water may be used if the levels of impurities are within acceptable limits Refer to Table 3 for Water Impurity Limits 14 TI D MS O ey Table 3 Recommended Maximum Allowable Impurities in Water for Battery Use gain ae In asus mu Owm O stage PI Positive plate shedding 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 gt Check that all vent caps are secured properly on the battery gt 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 gt Rinse with water and dry with a clean cloth gt Apply a thin coat of terminal protector spray that can be purchased through your local battery dealer gt Keep the area around batteries clean and dry 4 4 Charging amp 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 flooded 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
23. s high resistance and can cause terminal meltdown 6 BS D MS O ey Flooded ELPT EUT Cable Lug Nut Torque to 95 105 in Ibs 11 12 Nm Nut Torque to 95 105 in Ibs 11 12 Nm Washer Washer Terminal Cable Lug Bolt Terminal EHPT EAPT Nut Torque to 95 105 in Ibs 11 12 Nm Washer Stud Portion Terminal AP Connector Torque to 50 70 in lbs 6 8 Nm Cable Lug AP Connector Torque to 50 70 in lbs 6 8 Nm Terminal DT Cable Lug Nut Torque to 95 105 in lbs 11 12 Nm Washer AP Terminal Nut Torque to 95 105 in Ibs 11 12 Nm Washer Cable Lug Bolt Terminal AP Connector Torque to 50 70 in lbs 6 8 Nm Stud Terminal IND Cable Lug Nut Torque to 100 120 in lbs 11 14 Nm Washer Bolt Terminal Images shown reflect correct hardware placement Hardware not supplied by Trojan Battery Company Nut Torque to 95 105 in Ibs 11 12 Nm Cable Lug Lock Washer APTerminal AP Connector Torque to 50 70 in Ibs 6 8 Nm Washer Stud Terminal Nut Torque to 70 n Ibs 8 Nm Washer Cable Lug Bolt 20mm M8 Terminal Bolt 16mm Torque to 85 95 in 1bs 10 11 Nm Lock Washer LT Adapter Lock Washer ST Lock Washer Bolt Torque to 85 95 in Ibs 10 11 Nm Washer Cable Lug Terminal Nut Torque to 120 180 in Ibs 14 20 Nm Cable Lug Terminal
24. y is being overcharged which can reduce battery performance and life gt Check battery cables and connections Replace any damaged cables and tighten any loose connections Refer to Torque Values Section 3 5 4 2 Watering flooded wet batteries only 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 Water should NEVER be added to deep cycle AGM or gel batteries Standard Batteries gt 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 gt Check the electrolyte levels by removing the vent caps and placing them Plus Series batteries upside down so that dirt does not accumulate on the underside of the cap For Plus Series batteries simply flip open the cap gt If the electrolyte level is well above the plates then it is not necessary to add more water gt Ifthe 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 gt After adding water secure vent caps back ont
25. you use the manual method charger has adjustable settings follow the steps below gt Boost charge at CONSTANT CURRENT without voltage limit at 3 of Cz until the voltage stops increasing for three consecutive hourly readings If using CONSTANT VOLTAGE the recommended boost charge voltage is 2 58Vpc with the charger output current limited to 3 5 of Cy The minimum recommended value is 2 45Vpc however this will result in an extended boost time gt The boost charge is not complete until the specific 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 16 AN Bede ey 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 gt Boost charge at a CONSTANT VOLTAGE of 2 40 VPC with the current limited to 20 of Czo Example 20 amps for a battery with a Cz of 100Ah gt The time needed to boost charge the cells can be determined using the equation below DOD X Capacity at 20Hr Rate Boost Charge Time in Hours 5 Hours Maximum Charge Curr
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