Industrial Line USER'S GUIDE
Contents
1. a A be A A 0 Customer Date of Service Address Time of Service Date Purchased Distributor Name Controller Type Service Engineer Controller Status Load Shed Boost Hoat Fault Cell Type Battery Voltage V Cell No Specific Gravity Cell Voltage Cell No Specific Gravity CellVoltage CellNo Specific Gravity Cell Voltage 1 21 41 2 22 42 3 23 43 4 24 44 5 25 45 6 26 46 7 27 47 8 28 48 9 29 49 10 30 50 11 31 51 12 32 52 13 33 53 14 34 54 15 35 55 16 36 56 17 37 57 18 38 58 19 39 59 20 40 60 Pilot Cell Temperature Pilot Cell Temperature Pilot Cell Temperature Battery Check List circle answer Boost Charge if applicable Battery Tops Clean and Dry Yes No Boost Current A Ensure Vent Caps are Clean and Tight Yes No Duration of Boost Charge H Battery Terminal Connections Tight Yes No End of Charge Cell S G Max Min Terminal Connection Safety Caps Replaced Yes No End of Charge Cell Volts Max Min Electrolyte Levels As found Correct High Low End of Charge Max Cell Temp HC As left Correct High Low Remarks 4009 DOT NIVW GNI 700077 14 Battery Acronyms AC Alternating Current MM Millimeters AMP A Amperage M2. b On Charge Voltage Testing Equipment needed gt Voltmeter or Multi Meter gt Battery Maintenance Log Sheet gt gt gt Rubber Gloves Goggles Apron Rubber Boots On charge voltage testing is a secondary test to verify that there is a problem if the specific gravity test indicates something was wrong An on charge voltage test is done when there is a load connected to the battery This test indicates if the charge controller is working properly gt Disconnect and reconnect the DC power source to the charge controller to restart the charge controller manually if required gt While the batteries are on charge not float charging record the current in the last hour of charge if possible and measure the battery bank voltage gt While the batteries are on charge measure the individual battery voltages with a voltmeter gt Ifany battery voltage is below 2 33V for 2V 4 66V for a 4V or 7 0V for 6V battery and a voltage variation is greater than 0 17V for a 2V battery 0 33V for a 4V battery 0 5V for 6V battery from one battery to another in a set it may indicate a failed battery gt Record data on the Battery Maintenance Log Sheet for warranty Determine if there is a bad battery in he set replace if necessary gt If any battery voltage variation is greater than 0 33V for 2V 0 47V for 4V or 0 7V for 6V battery from any other battery in the battery bank equalize the battery bank Refer to Equalizing
3. gt Rubber boots or rubber soled shoes gt gt Insulated handled wrench gt gt Voltmeter multi meter gt gt Battery charger gt b Inspection Lined rubber gloves Distilled water Terminal protector NO OX ID grease Hydrometer Sodium Bicarbonate Solution 1 cup of baking soda to 1 gallon of water 150 gram liter Cables Vent Cap Terminal Protector Handles Outer Case When you receive your batteries for the first time follow these steps If any problems are detected with the batteries contact Trojan technical support or contact your battery distributor If damage occurred in transit contact your freight carrier INDUSTRIAL LINE USER S GUIDE gt Conducta visible inspection Check for visible damage including cracks dents deformation and other visible abnormalities The tops of the batteries and terminal connections should be clean free of dirt and corrosion and dry Any fluid on or around the battery could indicate that the case is not properly sealed or that the battery has been over watered Ensure that there is one cable per battery gt Check the battery s state of charge Trojan batteries are fully charged and tested before they are shipped but all batteries self discharge when they are not in use which can occur during transportation and storage The best way to determine a battery s state of charge is to check the specific gravity of the battery using a hydrometer For instr
4. Series Example Individual Battery Unit IND33 2V Voltage Capacity 2 1 794Ah at C Battery Bank in Series Twelve IND33 2V Batteries in Series Voltage Capacity 24V 1 794Ah at C INDUSTRIAL LINE USER S GUIDE Parallel Example Individual Battery Unit IND33 2V Voltage Capacity 2V 1 794Ah at C Battery Bank in Parallel Two IND33 2V Batteries in Parallel Voltage Capacity 2 1 794Ah 1 794Ah 3 588Ah at C ote While this example illustrates how to connect batteries in parallel most renewable energy applications will reguire a 12V 24V or 48V battery bank due to the inverter input voltage settings Series Parallel Example Individual Battery Unit IND33 2V Voltage Capacity 2V 1 794Ah at C Oo n TROJAN BATTERY Battery Bank in Series and Parallel Twenty Four IND33 2V Batteries in Series and Parallel Battery Bank Voltage Battery Bank Capacity 2V x 12 units 24V 1 794Ah x 2 3 588Ah at C b Battery Orientation Flooded wet batteries must be placed upright at all times Liquid electrolyte in the battery may spill if the battery is placed on its side or at an angle Due to the dual container design of the Industrial Line Trojan recommends installing the batteries in a battery room on a sealed concrete or brick floor If and when the batteries are installed in a battery rack designed for the Industrial line
5. a metal object as this can create a short circuit Wear protective rubber gloves rubber boots and eye protection at all times when working on batteries e Terminal Protection Installation Trojan 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 INDUSTRIAL LINE USER S GUIDE gt The protector has two locating pins that fit through the holes of the terminal gt The protector is made of two parts that are held together with a simple latch that snaps through a lock clip To remove the protector simply squeeze the latch pins toward the center to clear the latch while pulling gently on each part Do not use excessive force as the part or latch could break gt Once the cable connection is in position determine which knockout to remove on the protector so the cover will slip over the cable end and the two parts of the protector will latch back together There are four locations to choose to cover most installations To remove the knockout simply twist or remove with pliers gt Remove the locating pin in the large half of the protector where the cable goes through the terminal hole to allow the part to snap in place and back together If the terminal has two cables connected to it both pins should be rem
6. above the tops of the battery terminal posts of the top row of batteries to permit access for maintenance or removal replacement Each battery should be accessible for the addition of distilled water and for taking voltage and hydrometer readings Environment Batteries should be stored in a clean cool and dry place The location should be selected to keep water oil and dirt away from all batteries If any of these materials are allowed to accumulate on the batteries they can cause tracking and voltage leakage that can lead to self discharge and possible short circuiting Temperature The recommended operating temperature range is between 5 to 120 F 15 C to 49 C with a humidity of lt 90 Elevated temperatures can reduce operating life and lower temperatures can reduce battery performance Temperatures below freezing must be avoided when batteries are in a discharged condition The electrolyte may freeze which can ruin the cells Refer to the Capacity vs Temperature graph on page 7 It is important to minimize temperature variations between the cells To avoid temperature variation between the cells do not arrange the batteries where they are too tightly packed restricting airflow The minimum recommended spacing between the battery units is 1 inch 25 mm Do not locate the batteries near HVAC ducts or exhausts heat sources i e equipment that generates heat or in direct sunlight INDUSTRIAL LINE USER S GUIDE Ventilat
7. problem is indicated gt Record data on the Battery Maintenance Log Sheet for warranty While other methods of testing batteries exist including internal resistance i e CCA testers and carbon pile discharge testers these are not suitable testing methods for deep cycle batteries INDUSTRIAL LINE USER S GUIDE 10 Battery Recycling Lead acid batteries are more than 97 recyclable In fact lead acid batteries top the list of the most highly recycled consumer products and Trojan Battery supports proper recycling of your battery to keep the environment clean Lead acid batteries should never be discarded as household waste Please contact Trojan Battery to find out the nearest recycling facility in your area 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 recycling Recycling For A Better Environment At the recycling facility used batteries are broken apart and separated into components to begin the recycling process a oy A 9 DS ae s te Plastic Lead Electrolyte Option 1 Electrolyte Option 2 Plastic pellets recycled from Lead ingots recycled from Sodium sulfate crystals At some recyclers used battery cases and covers are battery grids other battery separated from used electrolyte electrolyte is reclaimed and used to ma
8. straps of the opposite polarity The natural plating action of the element during the discharge and charge helps to accumulate the particles to form the moss looking material that eventually shorts the cell Trojan Industrial batteries have plastic shields with fingers that fit under the straps between the plate lugs on both the positive and negative plates that insulate the tops of the plates preventing shorts due to moss buildup Nominal Voltage The cell voltage that is accepted as an industry standard For lead acid batteries this is 2V The battery bank nominal voltage is the total voltage reached by adding the number of individual 2V cells that are connected in series within one string and multiplying it by 2V For example a battery bank configured as one string or up to 3 strings in parallel with each string consisting of 12x 2V cells the battery bank voltage is 12 x 2V 24V Open Circuit Voltage OCV Open circuit voltage is the difference in electrical potential between two terminals of a device when disconnected from any load or circuit Open circuit voltage indicates a good yet imperfect indication of a battery s state of charge The higher the OCV the higher the battery s state of charge Open circuit voltage can be measured using a voltmeter but the preferred method to determine a battery s state of charge of a flooded lead acid battery is to check the specific gravity SG of the electrolyte using a hydrometer
9. the batteries should sit on the bottom of the rack and should not be suspended by the handles Trojan doesn t provide battery racks Please contact your Renewable Energy supplier for racks INDUSTRIAL LINE USER S GUIDE OG Battery Maintenance The following is the recommended minimum schedule for proper maintenance and record keeping Readings should be taken when battery is at full state of charge and no load The Trojan Industrial line warranty requires that records be kept on the Battery Maintenance Log Sheet example on pages 40 41 and is available for download on our website at www trojanbatteryRE com Wear protective rubber gloves rubber boots and eye protection at all times when working on batteries A A v v 7v v v v v v LOQ Rec Rev Rec Rec and Revi Inspect Monthly Revi ew general appearance and cleanliness of battery and battery area Check electrolyte levels by removing vent caps and looking into vent wells for evidence of voltage leaks on ground Check for cracks in cells or leakage of electrolyte ew terminals and connectors for corrosion ord ambient temperature so there is a record of the temperature history iew condition of ventilation equipment ord cell voltage using a voltmeter ord specific gravity using a hydrometer and electrolyte temperature with a hydrometer a thermometer gt Check charge controller or inverter charger settings for manufacturer recommendati
10. the battery voltage but the amp hour capacity will stay the same For example two batteries rated at 2V and 1 780Ah at C that are connected in series will result in 4V at 1 780 Ah Short Circuit Current An electrical circuit that allows current to travel along an unintended path often where essentially no or very low resistance is encountered INDUSTRIAL LINE USER S GUIDE Solar Charge Controller Inverter Charger A device used in a renewable energy battery based power supply system connected between the energy source and the battery bank that charges the battery bank using the energy source s and protects the battery bank from overcharge and over discharge Modern solar charge controllers Inverter chargers typically use pulse width modulation PWM or and multiple power point tracking MPPT constant voltage charge algorithms MPPT capabilities maximizes the power output from the solar energy source to the battery bank A system designed without a solar charge controller inverter charger that would not charge the battery bank adeguately nor have the adeguate charge protection may result in shortened battery life and decreased power availability to the load Specific Gravity SG Specific gravity isa measure ofthe acid concentration in the electrolyte within a battery This measurement is based on the density ofthe acid compared to the density of water and is typically determined by using a hydrometer By definition the s
11. Charge 2 58 15 5 31 62 Please contact Trojan technical support for guestions about charge controller or inverter charger specific settings for any major OEMs INDUSTRIAL LINE USER S GUIDE b Equalizing Equalizing is an overcharge performed on flooded wet batteries after they have been fully charged Trojan recommends equalizing only when fully charged batteries have a low specific gravity reading below 1 230 or wide ranging specific gravity 0 050 between the battery s cells An equalizing charge prevents battery stratification and reduces sulfation the leading causes of battery failure Individual cells will vary slightly in specific gravity after a charging cycle Equalization is a controlled overcharge at a higher voltage than is normally used in battery charging and it is required to bring each battery to a fully charged condition Equalization reduces sulfation and stratification two circumstances that shorten battery life Equalization can be performed by following this procedure gt Check the battery s electrolyte level in each cell to make sure the plates are covered with electrolyte before charging gt Check that all vent caps are secured properly on the battery before charging gt Set the charge controller or inverter charger to equalize mode Refer to the charge controller or inverter charger manual for information about how to program the device gt Note For a stand alone photovoltaic pv system an
12. EJ TROJAN BATTERY On Charge Voltage On charge voltage testing is a secondary test to verify problems if the specific gravity test indicates something is wrong An on charge voltage test is done when there is a load connected to the battery This test indicates if the charge controller is working properly Parallel Connection Connecting batteries in parallel positive to positive and negative to negative will increase the battery s amp hour capacity but the voltage will stay the same For example two batteries rated at 2V and 1 780Ah that are connected in parallel will result in 2V at 3 560 Ah Partial State Of Charge PSOC When a lead acid battery is not fully charged or discharged it is in a partial state of charge This is common with renewable energy applications since the intermittent nature of the sun and wind do not always fully charge a battery bank each day It is highly recommended to avoid letting batteries remain in a partial state of charge which could result in hard sulfation one of the major causes of lead acid battery failures Self Discharge When batteries are not in use they will lose their charge on their own This process is called self discharge The rate of self discharge depends on the ambient temperature cell chemistry and the length of time the batteries are not in use Batteries self discharge faster in warm temperatures Series Connection Connecting batteries in series positive to negative will increase
13. Ei Trojan Industrial Line USER S GUIDE BATTERY COMPANY 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 If you have any questions concerning safety precautions or for any assistance in installing or using the batteries in your system contact Trojan Battery Company s technical support engineers at the following numbers Sy TECHNICAL SUPPORT i 800 423 6569 Ext 3045 or 1 562 236 3045 www trojanbatteryRE com The Industrial Line User s Guide was created by Trojan application engineers and contains vital information regarding proper care and maintenance of your new Industrial batteries The guide includes information about safety instructions installation considerations and other valuable topics to help you install operate and maintain your Industrial batteries Please read through this guide carefully and completely before using your batteries It will help you achieve optimum performance and long life from your new investment Contents 01 o2 o3 o4 oS GettingStarted 5 a EguipmentNeedd 5 b lnspecion 2c es ek ee 5 c What to Expect from your Trojan Battery 6 General Safety Instructions 8 a Important Elec
14. GUIDE 13 Glossary of Terms Absorption Charge While a bulk charge only recharges a flooded lead acid battery bank to 85 90 SOC level the absorption charge continues the charging cycle to bring the flooded lead acid battery bank to approximately 97 99 SOC The absorption charge stage is achieved through a Constant Voltage CV mode Most solar charge controllers and inverter chargers allow you to adjust the duration of the absorption charge mode for the required time to bring the battery bank to the next step charge mode i e the floating charge mode or the periodic equalization charge mode Absorption charge voltage set points are outlined in Table 3 on page 23 A nominal full charge absorption charge floating charge is recommended every three charge throughputs Alternating Current Electricity comes in two forms direct current and alternating current Alternating current means electrons run back and forth rapidly in opposing directions causing the polarity of the current to alternate In the United States for example electrons run back and forth at a rate of 60 times per second i e 60 hertz In Europe and other markets the rate is 50 times per second i e 50 hertz While all lead acid batteries produce direct current it can be converted to alternating current by using an inverter Ampere A or A unit of electrical current flow referred to as Amps A or measured by how many electrons flow past a given point each s
15. NSTANT VOLTAGE conditions the recommended boost charge voltage is 2 58Vpc with the charger output current limited to 3 5 of the 20 hour capacity 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 initial boost charge contact Trojan Battery Company s technical support c What to Expect from your Trojan Battery gt It is expected that a new battery will need time to provide full peak capacity Trojan batteries take between 50 100 cycles to work up to providing full Amp hour capacity gt 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 Ws TROJAN BATTERY gt When operating batteries at temperatures above 80 F 27 C they will deliver more than the rated capacity but the battery life will be reduced Capacity vs Temperature 140 60 120 50 40 100 30 80 T g y 207 5 0 5 10 8 v 2 40 g E J E 20 10 o 20 20 30 40 40 0 20 40 60 80 100 120 Percent of Available Capacity gt The life of a battery varies by the temperature depth of discharg
16. PPT Maximum Power Point Tracking AH Amp hour NEC National Electric Code AWG American Wire Gauge Ocv Open Circuit Voltage Cc Celsius PSOC Partial State of Charge C RATE Charge Rate SG Specific Gravity DC Direct Current soc State of Charge DOD Depth of Discharge Vv Vol F Fahrenheit VPC Volt per Cell ISC Short Circuit Current W Watt LB Pounds IN nches Notes Ooo m TROJAN BATTERY Trojan Battery Company would like to thank you for selecting the Industrial 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 and press option 1 or 1 562 236 3045 or Visit www trojanbatteryRE com u A 2012 Trojan Battery Company All rights reserved his 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 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 rojan Battery Company reserves the right to make adjustments to this manual at any time without notices or obli
17. ainst the flat side of the lead battery terminal gt Place the stainless steel split spring washer on the end of the bolt that is protruding through the erminal against the flat washer gt Install the hex stainless steel M8 nut on the bolt and tighten the nut with your fingers Do not torque he bolts until all the cables are installed to allow some adjustment of position gt After all connections are assembled torque all stainless steel connector bolts to 100 120 inch lbs 11 3 13 6 Newton Meters Nm gt Using a paintbrush apply a light coat of the heated NO OX ID grease to the bolted connection making certain to coat the cable lug and stainless steel bolt washers and nut are coated Do not apply he NO OX ID grease to the cable insulation or the plastic parts of the battery ake certain the flat side of the cable lug is bolted directly to the lead terminal of the battery Do not place a washer or any other material other than the light film of NO OX ID grease between the cable ug and the lead terminal as this can create increased resistance which can generate heat and destroy he terminal the cable and become a fire hazard A loose connection between the battery cable and the battery terminal can have the same result Make sure that all bolted battery connections are torqued to he recommended values Use wrenches with a rubber handle to tighten all connections Be cautious not to touch both terminals at the same time with
18. al Boost Charge in page 6 to learn about initial boost charging and refer to Table 4 below for nominal specific gravity and voltage measurements at 80 F 27 C Specific gravity changes as the battery ages causing the range to be 7 points depending on the age of the battery gt When batteries are taken out of storage recharge them with another initial boost charge before use Note When taking specific gravity readings corrections must be made for variations in temperature of the electrolyte Correct the specific 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 Table 4 Percentage Charge Specific Gravity Open Circuit Voltage per Cell 100 260 2 11 90 246 2 09 80 1 227 2 07 70 207 2 05 60 187 2 03 50 1 165 2 01 40 142 1 99 30 1 119 1 96 20 096 1 94 10 072 12 Storage in Hot Environments greater than 90 F or 32 C When storing your batteries avoid direct exposure to heat sources if possible 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 two to four weeks Storage in Cold Environments less than 32 F or 0 C When storing your batteries avoid locations where freezing temperatures are expected if possible Batteries can freeze in cold tempera
19. atteries to maintain a full SOC by supplying constant voltage to the batteries The solar charge controller inverter charger determines when a float charge is needed and is typically based on a timer and or other parameters A float charge is conducted once the absorption charge is complete and compensates for the self discharge of a lead acid battery at a set voltage Gassing Hydrogen and oxygen are released when water molecules split as lead acid batteries are charged and discharged Hydrometer A hydrometer is a tool used to measure the specific gravity SG of the electrolyte within a flooded lead acid battery The SG of the electrolyte indicates the battery s state of charge INDUSTRIAL LINE USER S GUIDE Initial Boost Charge An initial boost charge is a charge given to batteries to correct possible voltage imbalances between individual cells or correct a battery that has self discharged after shipment or while in storage An initial boost charge restores the battery to its full state of charge and involves a short period of overcharging which releases gas and mixes the electrolyte to prevent stratification In addition an initial boost charge assists in keeping all batteries in a battery bank at the same capacity Mossing When shed material gets into the electrolyte and is lifted by gassing it can be deposited on the top or sides of the element where it can build up growing like moss to form shorts when it reaches plates or
20. ause terminal meltdown See page 14 for cable ins instructions b Cable Size If the system ocation on tant to ensure placed on top e because tallation Battery cables come in different sizes and it is important to choose the correct battery cable size for your system Battery cables should be sized to handle the expected load All series cables cables in a system should be the same length so that all strings have the same resistance and all parallel gt Trojan Battery provides a 4 0 cable and hardware with our Industrial batteries one per battery for series connections however it is important to determine the appropriate cable size for your application Parallel cables and output cables are not included but can be purchased from your preferred renewable energy supplier gt When choosing the battery cable size always assume that any string can end up being used to provide the full load current in the event of faulty strings gt All cable sizing is the responsibility of the installer gt For correct cable wire sizing refer to the National Electrical Code which is located at www nfpa org INDUSTRIAL LINE USER S GUIDE c Torque Values Tighten all cable connections to the proper specification to make sure there is good contact with the terminals Over tightening the connection to the terminal can result in terminal breakage and loose connections which can result in meltdown or fire Refer to Table 1 for the p
21. battery over a period of time For example a battery rated at 1 500 cycles at 80 depth of discharge will outlast a battery rated at 1 000 cycles at 80 depth of discharge since it is capable of 500 more cycles at that discharge rate Depth of Discharge DOD Depth of discharge DOD describes how much of the total amp hour capacity is used during a discharge and 500 amp hours are discharged from the battery the battery has reached a 50 DOD Deep cycle batteries cycle For example if a battery has a rated amp hour capacity of 1 000 amps hours at Cy are designed to discharge up to 80 of their rated capacity without damage to the battery The total number of cycles a battery can achieve in its life decreases as the level of DOD increases For example a battery that is regularly discharged to 80 DOD will achieve fewer cycles than a battery that is regularly discharged to 20 DOD Direct Current DC Electricity comes in two forms direct current and alternating current Direct current means electrons run continuously in one direction All lead acid batteries and photovoltaic PV modules produce direct current Direct current can be converted to alternating current by using an inverter Electrolyte An electrically conductive solution in which current flows due to the movement of ions In a flooded lead acid battery the electrolyte is a liquid solution made up of sulfuric acid and water When a flooded lead acid battery is used hydrogen a
22. e frequency of usage level of maintenance and ambient conditions The following graph shows the number of cycles for a Trojan Industrial battery at Go operating at 80 F 27 C Typical Cycle Life of a Trojan Industrial Battery in a Stationary Application 6000 5000 4000 3000 Number of Cycles 2000 1000 20 30 40 50 60 70 80 90 100 Depth of Discharge INDUSTRIAL LINE USER S GUIDE O2 General Safety Instructions a Important Electrical Safety Instructions A battery can present a risk of electrical shock and high short circuit current The following precautions should be observed when working with batteries Failure to observe the precautions may result in injury or loss of life Warnings in this manual appear in any of three ways Danger The danger symbol is a lightning bolt mark enclosed in a triangle and is used to indicate imminently hazardous situations locations and conditions which if not avoided WILL result in death serious injury and or severe property damage Warning The warning symbol is an exclamation mark in a triangle and is used to indicate potentially hazardous situations and conditions which if not avoided COULD result in serious injury or death Severe property damage COULD also occur Caution The caution symbol is an exclamation mark enclosed in a triangle and is used to indicate potentially hazardous situations and co
23. econd Amp Hour Ah A unit of electrical current over time One amp of current flowing for one hour is 1 Ah Amp hour is the standard measurement for battery capacity A battery s amp hours multiplied by its voltage equals watt hours Amp Hour Capacity The number of amp hours a battery can deliver for a specific period of time Ah capacity is rated by a Grate which indicates how many hours the battery can discharge the stated amp hours for a period of time For example a battery rated at 1 000 amp hours at C at 1 75Vpc will discharge 50 amps for 20 hours to a cutoff voltage of 1 75V per cell MT TROJAN BATTERY Battery Bank A group of batteries electrically connected together configured as one string or up to three strings in parallel Each string consists of the necessary number of battery units in series to reach the battery bank voltage Battery Capacity The total amount of electrical energy available from a battery usually expressed in amp hours at a particular Crate unit voltage cutoff voltage per cell Vpc and at a reference temperature Bulk Charge The first part of the battery charging process is typically a Constant Current CC charge mode when the maximum amount of current flows into the battery until a desired voltage is reached typically called the gassing voltage or absorption setting voltage A bulk charge normally charges a flooded battery to 85 90 SOC level Bulk charge voltage set points are outl
24. equalize charge can only happen when there is enough sun to fully charge the batteries which may not occur daily gt The batteries will gas bubble during the equalization process gt Measure the specific gravity of each cell of each battery every hour Discontinue the equalization charge when the gravity no longer rises The length of time to equalize a battery bank depends on he size of the system the power source and the system components gt Trojan recommends any automated system should be set to equalize Industrial batteries at least every 30 nominal charge throughputs A full charge is recommended at least every three nominal charge throughputs A charge throughput is when a battery is taken from the end of charge is discharged and then taken to the end of charge again A nominal charge throughput is reached when the sum of the discharge currents corresponds to the nominal capacity of the battery c Storage gt Always do an initial boost charge to your batteries before placing them in storage gt Store in a cool dry location protected from the elements gt Disconnect from equipment to eliminate potential parasitic loads that may discharge the battery gt Batteries gradually self discharge during storage Monitor the specific gravity or voltage every four TROJAN BATTERY to six weeks Stored batteries should be given another initial boost charge when they are at 70 state of charge SOC or less Refer to Apply Initi
25. es rings earrings or other metal objects Use tools with insulated handles Always wear protective clothing goggles lined rubber gloves and rubber boots Do not lay tools or metal parts on top of batteries Always keep the batteries in an upright position So POND p Determine if the battery is grounded see Grounded and Ungrounded Batteries on page 10 If the system is grounded remove the source of ground Contact with any part of a grounded battery can esult in electrical shock The likelihood of such shock will be reduced if such grounds are removed during installation and maintenance Protective grommets on positive cable connectors to the battery cell terminals should be in position when not working directly on a specific terminal on any battery or cell within the system 10 Verify circuit polarities before making connections by using a voltmeter or multi meter 11 Flooded lead acid FLA batteries can contain an explosive mixture of hydrogen gas Do not smoke near batteries Keep sparks flames and metal objects away from batteries This includes static electricity from the body and other items that may come in contact with the battery 12 Charge and store batteries in a well ventilated area 13 Batteries can be heavy Use proper lifting techniques when moving batteries 14 Only dispose of lead acid batteries through channels in accordance with local state and federal regulations Batteries must NEVER be disp
26. evices should meet all local state and country codes and all industry standards Floor anchoring seismic requirements and equipment specifications and its design are the responsibility of the user Trojan Battery Company does not supply racking systems with its batteries Use of any rack design is the responsibility of the battery system user MT TROJAN BATTERY o4 A 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 terminal connections cable sizing torque values and terminal protection a Terminal Connections Each battery has a positive and negative terminal that is clearly marked on the top of the battery Battery cables are connected to the battery terminals and run from one battery to the next to create a battery bank Batteries can be connected in series and or parallel see pages 17 19 design requires more than one cable per terminal bolt the second cable to the same each terminal of the same battery Il When using a washer to connect a battery cable to a battery terminal it is very impor the battery cable is contacting the lead surface of the terminal and that the washer is of the cable Do not place the washer between the terminal lead and the battery cabl it creates high resistance and can c
27. gation Trojan Battery Company the Trojan Battery Company logo T2 Technology Maxguard T2 Separator Alpha Plus Paste HydroLink Plus Series Polyon tansPower and OverDrive AGM 31 are either registered trademarks or trademarks of Trojan Battery Company INDUSTRIAL LINE USER S GUIDE Trojan batteries are available worldwide Tro We offer outstanding technical support provided by full time application engineers KT TRE call 800 423 6569 or 1 562 236 3045 or visit www trojanbatteryRE com Clean energy for life 12380 Clark Street Santa Fe Springs CA 90670 USA 2012 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 ZLZO apindsiasn 609 LONTHL
28. h he watering procedure below gt Only add distilled water to the battery Tap water river water filtered water etc all contain minerals hat can shorten the battery s life In cases where no distilled water is available use the cleanest water possible It is more important to water the batteries with the cleanest water possible than to allow the plates to be exposed from lack of watering gt After adding water secure the vent caps back on the batteries gt In cold climates with unheated battery rooms water should only be added when the battery temperature is 45 F 7 C or above gt Do not store water in a metal container Use a clean container made of glass rubber or plastic The container should not have been used to store anything but water in the past gt Ifyou have purchased a single point watering system from Trojan Battery please refer to the associated IOM Installation Operation and Maintenance manual Visit www trojanbatteryRE com to obtain more information about the single point watering system we TROJAN BATTERY os Charging and Equalizing a Charging Proper charging is imperative to maximize battery performance Both under or over charging batteries can significantly reduce the life of the battery For proper charging refer to the instructions that came with your charge controller and or inverter charger Most charge controllers and inverter chargers are automatic and pre programmed but they a
29. id spills To find the specific gravity of your battery s cells follow these steps gt gt gt Use a hydrometer that measures within five grading points or less Fill and drain the hydrometer with electrolyte two three times before drawing a sample from the battery Take a sample of the electrolyte The sample must be large enough to completely support the float Hold the hydrometer in a vertical position so the float is not touching the sides top or bottom of the ube Look straight across the electrolyte level to read the float as shown above Record the specific gravity readings for all battery cells on your Trojan Battery Maintenance Log Sheet Correct the specific 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 f every cell in the battery bank is below 1 230 the batteries may be undercharged recharge batteries f any battery has a specific gravity variation of more than 0 050 between cells equalize the battery bank For information on Equalization refer to page 24 f there is still a variation of more than 0 050 between cells after equalizing it may indicate a failed battery If this occurs contact Trojan technical support After testing rinse the hydrometer out with fresh water at least five times to flush the acid out A refractometer can also be used to measure specific gravity INDUSTRIAL LINE USER S GUIDE
30. ined on page 23 Charge Rate Crate Battery capacity is rated in amp hours at a specific charge rate The charge or discharge rate indicates how many hours the battery can discharge the stated amp hours for a rated period of time For example a battery rated at 1 000 amp hours at C at 1 75Vpc will discharge 50 amps for 20 hours to a cutoff voltage of 1 75V per cell Cell Lead acid batteries are made up of individual cells which are 2V each The Industrial battery units configure in individual 2V cells assembled in 6V 4V in dual container configurations or only one 2V cell in dual containers for the 2V larger capacity models Battery banks combine several Industrial battery units together to form a battery bank with higher amperage and voltage than one individual Industrial battery unit can provide Charge Voltage The voltage that is applied to each 2V cell during each Constant Voltage charging stage absorption float or equalization charge mode The voltage settings for the Industrial flooded lead acid batteries are provided at Table 3 page 23 INDUSTRIAL LINE USER S GUIDE Current The rate of the flow of electrons in a circuit measured in amperes Cycle Cycle Life A cycle is a term used to describe the concept of discharging a battery to a particular state of charge and then fully recharging the battery Lead acid batteries are rated in cycle life which gives the user an indication of the useful life of the
31. ion A Codes Floor Anchoring Racks Flooded wet lead acid batteries release small amounts of hydrogen and oxygen gas during usage particularly during the charging process Adequate ventilation must be provided to prevent hydrogen gas from exceeding a 2 concentration The battery containment area must be designed and set up where the hydrogen accumulation can be limited to less than 2 of the total volume of the battery area to prevent possible explosion or flash burn Flame propagation can begin at 2 but pockets can accumulate at higher percentages so it is important to keep levels below 2 Ventilation must be adequate to ensure that pockets of trapped hydrogen gas do not develop particularly at the ceiling For more assistance in calculating ventilation needs please contact Trojan Battery Company s technical support Building codes and fire codes may require special monitoring unique electrical installation requirements and switch gear fire protection and spill containment systems for battery installations Please consult local building codes Batteries should be kept on a level surface Sealed concrete epoxy coated concrete or membrane installed acid brick system capable of supporting the weight of the battery system and any associated equipment is preferable Shim up to 1 4 inch per foot 6 mm per 305 mm maximum to level battery rack or cabinet or shelving front to rear and side to side Anchoring and isolation d
32. ion 1 cup of baking soda to 1 gallon of water 150 gr 1It Do not allow cleaning solution to get inside the battery 5 Wipe down top and sides of battery with sodium bicarbonate solution and then wipe dry with a clean cloth Do not allow cleaning solution to get into battery Ifa spill occurs take appropriate action to contain any spill Neutralize any spills with the sodium bicarbonate solution c Terminal and Connector Cleaning Mild Corrosion In cases where mild corrosion on the terminals or connectors is present using the same sodium bicarbonate solution that was used to clean the top of the battery take a soft bristled brush and gently brush down all terminals and wipe dry with a clean cloth Reapply a light coating of No Ox Id to all connections Heavy Corrosion In cases where heavy corrosion on the terminals or connectors is present unbolt and remove all connectors apply the sodium bicarbonate solution mentioned above AN to cell posts and connectors to neutralize the corrosion Clean contact surfaces by rubbing posts and terminals with non metallic stiff bristle brush or non metallic A scouring pad Do not remove the plating from the connectors If copper is exposed on connectors replace the cables If the cables need to be replaced follow the same process outlined for originally attaching the connectors see page 14 Keep the area around batteries clean and dry INDUSTRIAL LINE USER S GUIDE 07 Watering It is importan
33. lso allow the user to set the voltage and current values manually Refer to Table 3 below for Trojan s recommended voltage setting points for the Industrial line gt Check each battery cell s electrolyte level to make sure the plates are covered with electrolyte before charging gt Check that all vent caps are secured properly on the battery before charging gt Make sure the charge controller and or inverter charger is set to the appropriate charge algorithm for flooded wet batteries gt Lead acid batteries do not have a memory effect and therefore do not need to be fully discharged before recharging 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 gt Charge batteries only in well ventilated areas since they release hydrogen and oxygen gas gt Flooded wet batteries will gas bubble towards the end of charge to ensure the electrolyte is properly mixed gt Never charge a frozen battery gt Avoid charging at temperatures above 120 F 49 C if possible to maximize the battery life Table 3 Charge Controller and or Inverter Charger Voltage Settings for Trojan Industrial Flooded Batteries System Voltage 2V 12V 24V 48V Absorption Charge 2 35 245 141 147 28 2 294 56 4 58 8 Float Charge DD 52 26 4 52 8 Equalization
34. nd oxygen escape through the vent caps requiring distilled water to be added to each battery cell periodically to ensure the electrolyte always covers the lead plates ES TROJAN BATTERY Equalization Equalizing Charge An equalizing charge prevents battery stratification and reduces sulfation the leading causes of battery failure The equalization charge stage is achieved through Constant Voltage CV mode It is a controlled overcharge at a higher voltage than is normally used in the float battery charging stage and is required to bring each battery plate to a fully charged condition Trojan recommends equalizing the Industrial batteries every 30 nominal charge throughputs To equalize your batteries set your solar charge controller inverter charger to equalization or manually charge the batteries until voltage elevates to the equalization voltage shown on page 23 A constant specific gravity reading taken every 30 minutes is a good indication of cell equalization Float Charge A float charge is the final stage in the three stages of charging which includes bulk and absorption charging and occurs when a battery is approximately at 97 99 SOC and no load is drawing on the batteries The charge current and voltage are reduced to maintain a full battery providing just enough charging to compensate for self discharge It is a controlled constant voltage CV at a lower voltage than the absorption battery charging stage and allows the b
35. nditions which if not avoided may result in injury Equipment damage may also occur Other warning symbols may appear along with the Danger Warning and Caution symbols and are used to specify special hazards These warnings describe particular areas where special care and or procedures are required in order to prevent serious injury and possible death Electrical Warnings The electrical warning symbol is a lightning bolt mark enclosed in a triangle The electrical warning symbol is used to indicate high voltage locations and conditions which may cause serious injury or death if the proper precautions are not observed Explosion Warnings The explosion warning symbol is an explosion mark enclosed in a triangle The explosion warning symbol is used to indicate locations and conditions where molten exploding parts PP PEP may cause serious injury or death if the proper precautions are not observed 1 Make sure all power sources to the batteries are off or disconnected from the batteries so they are not being charged while you are working on them Disconnect all loads from the batteries before connecting or disconnecting terminals See Cable Installation Instructions on page 14 2 Use appropriate lockout tag out procedures according to the appropriate code M TROJAN BATTERY gt gt 3 If working on an installed battery bank disconnect the battery in sections to reach safe working voltage levels Remove all watch
36. nufacture new parts e g posts and terminals dilute sulfuric acid is recycled reused in manufacturing new cases and covers and lead oxide are used to and sold for use in textiles batteries At others it is manufacture lead for new glass and detergent neutralized and managed Crush the case grids parts and lead oxide manufacturing according to federal and state water permits Neutralize electrolyte Lead ingots gy Q Plastic pellets BPD c O 6 rea lt A sulfate New Grids and erystals Lead Oxide New battery grids are manufactured from recycled IB New Covers lead Recovered lead oxide an ases is also used in new Electrol Eke l New battery covers and cases battery manufacturing gt Elect Eka E so 22 are manufactured using Lead Oxide Glass textiles lay Aasen to tesatedi td recycled plastic pellets detergent 4 a water reused New cases treatment and covers M a E plant New Battery EJ TROJAN BATTERY 11 12 Warranty Information Trojan s Industrial line of flooded deep cycle batteries is covered by an 8 year warranty period some restrictions may apply Please refer to the full RE warranty document at www trojanbatteryRE com tech_support literature for more information Battery Maintenance Log Sheet A sample of Trojan s Battery Maintenance Log Sheet is on page 40 41 Visit www trojanbatteryRE com tech_support to download a full size form INDUSTRIAL LINE USER S
37. on page 24 After equalizing the battery bank re measure the individual battery voltages If any battery voltage variation is still greater than 0 33V 0 47V or 0 7V respectively from any other battery in the battery bank you may have a failed battery t c Open Circuit Voltage Testing Equipment needed gt Voltmeter or Multi Meter A gt Battery Maintenance Log Sheet gt Rubber Gloves Goggles Apron Rubber Boots TROJAN BATTERY Open circuit voltage testing is used to determine the battery s state of charge however it is not as accurate as a specific gravity test which measures each battery cell The test is done when the load is disconnected to the battery gt For accurate voltage readings batteries must remain idle disconnected for the power source and the oad at least 6 hours but preferably up to 24 hours gt Measure the individual battery voltages with a voltmeter gt Ifthe battery voltage difference is 0 33V for 2V 0 47V for 4V or 0 7V for 6V greater than the other batteries in battery bank equalize the battery bank Refer to page 24 for more information on Equalization After equalizing the battery bank re measure the individual battery voltages If any individual battery voltage is 0 33V for 2V 0 47V for 4V or 0 7V for 6V lower than any other battery in he battery bank you may have a failed battery gt Ifthe battery voltage is not greater than 0 3V than any other battery in the battery bank no
38. ons All of this information should be recorded on the Battery Maintenance Log Sheet and should be kept for the duration of the life of the battery Inspect Annually In addition to the monthly items also do the following checks on an annual basis gt Check all bolted connections to see if tightening required Tighten all bolted connections to the proper specifications listed on page 14 gt Check the integrity of the rack stand battery tray or other accessories as needed gt Check the area around the battery to ensure that nothing can fall on or short out the battery string This data will be required for any warranty claim made on the battery For battery bank protection and to suit local conditions requirements more frequent readings may be necessary or required EJ TROJAN BATTERY a Preventative Maintenance It is important to inspect the batteries for cleanliness at regular intervals and keep cell terminals and connectors free of corrosion Terminal corrosion may adversely affect the performance of the battery and it could present a safety hazard b Standard Cleaning 1 Disconnect the battery from the charging source and the load 2 Wipe off any accumulation of dust on the cell covers with a cloth dampened with clean water 3 Check that all vent caps are secured properly on the battery 4 If the cell covers or jars are damp with spilled electrolyte wipe with a cloth dampened with a sodium bicarbonate solut
39. osed in household waste For information about where to properly dispose your batteries at the end of their life contact Trojan technical support 15 The electrolyte in a battery is a solution of acid and water Avoid skin and clothing contact with the electrolyte If acid contacts skin or eyes flush with water immediately 16 NEVER add acid to a battery If for some reason a battery has leaked electrolyte contact Trojan Battery technical support for instructions about what to do b Electrical Shocks and Burns Battery banks can attain high voltage and or currents Do not touch non insulated batteries connectors or terminals To prevent serious electrical burns and shock use EXTREME CAUTION when working with batteries INDUSTRIAL LINE USER S GUIDE c Grounded and Ungrounded Batteries A grounded battery or battery bank occurs when a battery terminal is connected to the ground or when the battery racking is connected to the ground with a current carrying conductor Unintentional grounding can happen in a number of ways including direct wire coupling coupling off their power source electrolyte spilled from the battery and tracking If the battery bank is grounded it is recommended during installation and maintenance to disconnect the battery bank from the ground as it can pose a serious risk of shock or an unintentional short circuit If the battery or battery bank is grounded a shock hazard exists between all other
40. oved and both knockouts should be used in the large half of the protector The pin will snap off or can be cut off with snips If dual cables are utilized the protector will be held in place by the cables gt Only service one protector and make one connection at a time to assure the battery is not shorted or inadvertently grounded gt If the system is relocated and the connector will not work with the new installation replace with a new protector to assure the system is safe 6 TROJAN BATTERY OS Connecting Batteries to Increase System Power a Series vs Parallel Connections Batteries can be connected in series or parallel or a combination of both A series connection involves using a battery cable to connect the positive terminal of one battery to the negative terminal on another A series connection increases the voltage by adding the voltage of the connected batteries but amp hour capacity does not increase A parallel connection involves using a battery cable to connect the positive terminal of one battery to the positive terminal of another battery and a second battery cable to connect the negative terminal of one battery to the negative terminal of another battery A parallel connection increases the amp hour capacity by adding the amp hour capacity of the connected batteries but does not increase the voltage To increase both the voltage and amp hour capacity batteries can be connected in series and parallel Table 2
41. pecific gravity of water is 1 000 and the specific gravity of the sulfuric acid electrolyte in a typical fully charged Industrial battery is 1 260 Specific gravity measurements are used to determine if the battery is fully charged or if the battery has a weak or bad cell State of Charge SOC A measurement of the battery s charge is relative to its capacity State of charge can be determined by using a hydrometer to measure the flooded lead acid battery s specific gravity per cell or by using a voltmeter to measure the battery s cell voltage Stratification The unequal concentration of sulfuric acid within the electrolyte due to density gradients from the bottom to the top of the cell This condition is encountered most often in batteries recharged from deep discharge at constant voltage without a great deal of gassing Continued deep cycling of a stratified battery will result in softening of the bottoms of the positive plates Equalization charging is a way to avoid acid stratification of the electrolyte ES TROJAN BATTERY Sulfation Sulfation is the generation or conversion of the discharged lead sulfate in the plates to a state that resists normal recharge Sulfation develops when a battery is stored or cycled in a partial state of charge PSOC particularly at warm temperatures Terminal Every Trojan lead acid battery has two terminal a positive terminal and a negative terminal Battery terminals come in different shapes and
42. roper torque values based on the type of terminal on your battery Table 1 Torque values Terminal Type Torque Ib in Torque Nem IND 100 120 11 14 d Cable Installation Instructions Properly connecting the battery cable to the battery terminal is important to ensure that a solid electrical connection is made and to reduce the risk of injury system malfunction or fire To properly connect the cable to the terminal remove the terminal protectors as noted in the Terminal Protection Installation section on page 15 Lead Terminal Cable Lug M8 Flex Nut o _ M8 Hex Head Bolt Spring Washer Flat Washer Flat Washer gt Using asmall piece of steel wool or small wire brush clean the surface of the lead terminal on the side the cable lug will be bolted to gt Using a paintbrush apply a light coat of NO OX ID grease that has been heated in hot water just to the point of thinning to the contact surface of the terminal gt Place the flat side of the lug end of the cable directly on lead terminal surface gt Place one of the stainless steel flat washers supplied on the stainless steel M8 hex head bolt against the inside head of the bolt wy TROJAN BATTERY gt Place the hex head bolt with the installed washer through the cable lug and through one of the holes in the lead battery terminal gt Place the second stainless steel flat washer on the end of the bolt protruding through the terminal and ag
43. sizes depending on the intended application The terminals are connected to the plates inside the battery allowing the terminals to carry current from the battery to the cables Battery cables are connected to the lead terminals of the battery allowing multiple batteries to be connected together to an energy source and to a load Tracking Tracking is dust or mist that accumulates on the battery which connect it to the ground creating an unintentionally grounded battery Tracking should be avoided as it presents a potential safety hazard Volt V A unit of measurement of electrical potential or pressure Lead acid batteries come in 2V to 12V types and are made up of individual 2V cells Most renewable energy battery bank designs are 12V 24V or 48V The Industrial batteries configured as individual 2V cells that are assembled in series in 6V 4V models housed in dual container configurations or as a single 2V cell housed in dual containers for the 2V larger capacity batteries Voltmeter A voltmeter is an instrument used for measuring a potential electrical difference voltage between two points in an electric circuit Watt W A watt is a unit of measurement of energy Wattage is determined by multiplying amperage by voltage INDUSTRIAL LINE USER S GUIDE PHOTOCOPY BEFORE USING Trojan Report No BATTERY COMPANY BatteryMaintenanceLog 0312
44. t to periodically add distilled water to your flooded batteries The electrolyte level in a flooded lead acid battery will gradually lower over time as hydrogen and oxygen gasses are released through the vent caps due to electrolysis a normal battery process The rate at which the water in the electrolyte is depleted depends on the battery cell temperature and humidity The frequency of watering depends upon battery usage and operating temperatures Check new batteries every few weeks to determine the watering frequency for your application It is normal for batteries to need more frequent watering as they age When adding distilled water to your batteries please keep these points in mind gt Remove the vent caps from each cell and place them upside down so that dirt does not get on the underside of the cap Check the electrolyte level by looking into the vent wells gt Ifthe electrolyte level is barely covering the plates add distilled water to a level 1 2 13 mm below the vent well The plates should never be exposed Vent Well gt Ifthe electrolyte level is above the plates then it is not necessary to add more distilled water gt Only add distilled water to the battery when the battery is at full state of charge Only add water to discharged or partially charged batteries if the plates are exposed In this case add just enough water o cover the plates and then charge the batteries Once the batteries are fully charged continue wit
45. terminals and ground i e dirt and acid on top of battery cell touching terminals rack or any other ground If an unintentional ground develops within the already grounded system a short circuit may occur and cause explosion or fire gt gt For ungrounded batteries or battery banks an unintentional ground could develop causing an increased shock hazard that exists between the terminals and ground If a second unintentional ground develops within the already unintentionally grounded system a short circuit may occur and cause explosion or fire If you are required to work on a grounded battery system make absolutely sure you use the correct safety precautions equipment and clothing 0 TROJAN BATTERY O3 Installation Considerations When planning the system requirements for your Trojan Industrial batteries consider the following criteria gt Space gt Ventilation gt Environment gt Battery System Configuration Layout gt Temperature gt Floor Loading Material Preparation gt Distance from operating equipment gt Accessibility Traffic Maintenance gt Floor Anchoring Racking gt Moving Lifting batteries Space Trojan recommends that the aisle space provided in front of the battery bank be a minimum of 36 inches 915 mm The designer installer must verify the requirements for aisle space in all applicable local codes or regulations We recommend maintaining a minimum of 12 inches 305 mm of free space
46. trical Safety Instructions 8 b ElectricalShocksandBurns 9 c Grounded and Ungrounded Batteries 10 Installation Considerations 1 Battery Connections B a Terminal Connections 13 BAGAHIESIZE 14 og oo oa hoo oo 6 13 c Torg eValues soson at ew ce ont 14 d Cable Installation Instructions 14 e Terminal Protection Installation 15 Connecting Batteries to Increase System Power 17 a Series vs Parallel Connections 7 b Battery Orientation 19 OG 07 os 09 10 11 12 13 14 Battery Maintenance 20 a Preventative Maintenance 21 b Standard Cleaning 21 c Terminal and Connector Cleaning 21 Watering 32k eee tes eee 22 Charging and Egualizing 23 ESE 6 35 Soh Ooo ee an ooo B 23 b Egualizingi gt t eee ee ee 24 CBSE Gen Boi ava GG eel Gay oh 010 24 Troubleshooting 26 a Specific Gravity Testing 26 b On ChargeVoltageTesting 28 c Open Circuit VoltageTesting 28 BatteryRecycling 30 Warranty Information 31 Battery Maintenance Log Sheet 31 Glossary of Terms 32 BatteryAcronyms 42 01 Getting Started a Eguipment Needed The following is a list of equipment we recommend you have on hand as you inspect and care for your batteries gt Goggles gt
47. tures if they are not fully charged If batteries are stored during cold winter months it is critical that they are kept fully charged INDUSTRIAL LINE USER S GUIDE O9 Troubleshooting The following information includes three different battery testing procedures that are only guidelines for identifying a battery that may need to be replaced Unique situations may be observed that are not identified within these procedures Please contact Trojan Battery Company s technical support at 800 423 6569 Ext 3045 or 1 562 236 3045 for help interpreting the test data Please note that specific gravity and voltage readings recorded regularly on the Battery Maintenance Log Sheet must be provided for warranty claims Before testing your battery please follow these steps 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 sodium bicarbonate solution Do not allow cleaning solution to get inside the battery Rinse with water and dry with a clean cloth gt Check battery cables and connections replace any damaged cables and tighten any loose connections Refer to Torque Values Section 04 gt Check the electrolyte level and add distilled water if necessary For information on how to water your batteries refer to Watering Section 07 gt Fully charge batteries before conducting any tests a Specific Gravity Testing AN Eq
48. uctions on how to use a hydrometer please refer to page 27 The rate of self discharge depends on many factors including time battery type and the ambient temperature where the battery is stored so it is important to understand the battery s state of charge upon arrival to determine if an initial boost charge is needed When checking the specific gravity make sure the electrolyte level covers the plates but be sure not to overfill the battery as the level of electrolyte will rise during the charging process Refer to the Watering Section on page 22 for more information about adding distilled water to your batteries gt Apply initial boost charge Trojan recommends applying a boost charge to your new batteries A boost charge corrects voltage imbalances between individual cells and restores the battery to a fully charged state to maximize system performance The term boost charge refers to fully charging your batteries before they are used gt Two methods can be used to condition your new product One is to use the chargers that are automatic or pre programmed If this method is used allow the charger to go through the full cycle Some chargers allow the settings to be adjusted and to operate in a manual mode In this situation use the following settings gt Boost charging at CONSTANT CURRENT without voltage limit may be carried out as specified charge at 3 of Cy until the voltage stops increasing for three consecutive hourly readings Under CO
49. uipment needed gt A hydrometer gt Battery Maintenance log book gt Rubber gloves goggles apron rubber boots Sodium Bicarbonate Solution gt Water 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 The specific gravity of water is 1 000 and the specific gravity of the sulfuric acid electrolyte in a typically fully charged Industrial battery is 1 260 Specific gravity measurements are used to determine if the battery is fully charged or if the battery has a weak or a bad cell A high specific gravity means a higher density of acid to water which normally indicates a higher state of charge Specific gravity should be measured when the battery is not under a load and should not be measured soon after water is added to the battery MT TROJAN BATTERY Hydrometer Reading the Hydrometer While there are many hydrometers available on the market not all are designed for use with Trojan deep cycle Industrial batteries The Trojan Industrial Owner s Package includes a special Freas Glass Works Number 99 hydrometer For more information about the Industrial Owner s Package visit www trojanbatterRE com Wear eye protection rubber gloves and have sodium bicarbonate solution and water on hand in case of ac
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