Congratulations on your purchase from Trojan Battery Company, the manufacturer of the worlds 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.

TROJAN BATTERY USERS GUIDE

TROJAN BATTERY USERS GUIDE

This Users Guide was created by Trojans applications engineers and contains vital information regarding proper care and maintenance of your new battery. Please read through this users guide carefully and completely before using your battery. It will help you achieve optimum performance and long life from your new investment.

1. Equipment Needed

Gogglesandgloves Distilledortreatedwater(i.e.de-ionized,reverseosmosis,etc.) Rubber-handledwrench Bakingsoda Postprotector(i.e.petroleumjelly,anti-corrosionspray,etc.) Voltmeter(forflooded/wet,gelandAGMbatteries) Hydrometer(forflooded/wetbatteries) Dischargetester(ifavailable) Batterycharger

2. Battery Installation

Toensureyouinstallyourbatteriesproperlyandsafelypleaseusethefollowingguidelines:

2.1. Safety

Alwayswearprotectiveclothing,glovesandgoggleswhenhandlingbatteries Donotsmokenearbatteries Keepsparks,flamesandmetalobjectsawayfrombatteries Useawrenchwitharubberhandlewhenmakingbatteryconnections Theelectrolyteisasolutionofacidandwater,soavoidskincontact Ifacidcontactsyourskinoreyes,flushwithwaterimmediately Checkthatallcableconnectionstotheterminalareproperlytightened;connectionsthataretootightortooloosecouldresultinpostbreakage,meltdownorfire

Toavoidshortcircuitsdonotlayobjectsontopofbattery Chargebatteriesinawell-ventilatedarea Neveraddacidtoabattery

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Table of Contents

1. Equipment Needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

2. Battery Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22.1. Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22.2. BatteryConnections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

2.2.1. CableSize. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32.2.2. TorqueValues. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42.2.3. TerminalProtection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

2.3. Ventilation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42.4. ConnectingBatteriestoIncreaseSystemPower. . . . . . . . . . . . . . . . . . . . . . . . . . .5

2.4.1. SeriesConnections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52.4.2. ParallelConnections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52.4.3. Series/ParallelConnections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

2.5. BatteryOrientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

3. Preventative Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73.1. Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73.2. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73.3. Watering(flooded/wetbatteriesONLY)...................................7,83.4. ChargingandEqualizing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

3.4.1. Charging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9,103.4.2. Equalizing(flooded/wetbatteriesONLY). . . . . . . . . . . . . . . . . . . . . . . . .11

4. Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11,124.1. StorageinHotEnvironments(greaterthan90For32C) . . . . . . . . . . . . . . . . . . . .124.2. StorageinColdEnvironments(lessthan32For0C). . . . . . . . . . . . . . . . . . . . . . .12

5. How To Maximize the Performance of Your Trojan Battery. . . . . . . . . . . . . . . . . . . .13

6. What to Expect from Your Trojan Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

7. Trouble-Shooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147.1. PreparationforTesting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147.2. On-ChargeVoltageTesting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147.3. SpecificGravityTesting...............................................147.4. OpenCircuitVoltageTesting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157.5. DischargeTesting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

8. Battery Recycling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

TROJAN BATTERY USERS GUIDE

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2.2.2. Torque Values

Tightenallcableconnectionstotheproperspecificationtomakesurethereisgoodcontactwiththeterminals.Over-tighteningtheconnectiontotheterminalcanresultinterminalbreakageandlooseconnectionswhichcanresultinmeltdownorfire.RefertoTable 2forthepropertorquevaluesbasedonthetypeofterminalonyourbattery.

Table 2

Terminal Type Torque (lb/in) Torque (Nm)

AP 50 - 70 5.5 - 8

LT 100 - 120 11 - 13.5LPT, HPT, WNT, DWNT, UT 95 - 105 11 - 12

ST 120 - 180 13.5 - 20

* For DT (Automotive Post & Stud) refer to AP or ST type

WARNING: Use a wrench with a rubber handle when making battery connections.

2.2.3. Terminal Protection

Corrosioncanbuilduponterminalsiftheyarenotkeptcleananddry.Topreventcorrosionapplyathincoatofpetroleumjellyorterminalprotectorthatcanbepurchasedthroughyourlocalbatterydealer.

2.3. Ventilation

Flooded/wetleadacidbatteriesreleasesmallamountsofgasduringusage,particularlyduringthechargingprocess.GelandAGMbatteriesgenerallydonotreleasegasbutcaniftoomuchpressurebuildsupduringcharging.Itiscriticaltochargebatteriesinaproperlyventilatedarea.Formoreassistanceincalculatingventilationneeds,pleasecontactTrojanBatteryCompanystechnicalsupportengineersat800-423-6569or+1-562-236-3000.

2.2. Battery Connections

Batterycablesprovidethelinkbetweenthebatteries,equipmentandchargingsystem.Faultyconnectionscanleadtopoorperformanceandterminaldamage,meltdownorfire.Toensureproperconnections,pleaseusethefollowingguidelinesforcablesize,torquevaluesandterminalprotection.

2.2.1. Cable Size

Batterycablesshouldbesizedtohandletheexpectedload.Referto Table 1forthemaximumcurrentcarryingcapacity(amps)basedonthecable/wiregaugesize.

Table 1

Wire Gauge Size (AWG) Ampacity (amps)

14 25

12 3010 408 556 754 952 1301 150

1/0 1702/0 265

4/0 360

Tablevaluesareforcablelengthslessthan6feet(1829mm).Inseries/parallelbatterybanks,itispreferableforallseriescablestobethesamelengthandallparallelcablestobethesamelength.

FormoreinformationrefertotheNationalElectricCodeforcorrectcable/wiresize,whichcanbelocatedatwww.nfpa.org.

TROJAN BATTERY USERS GUIDE

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2.4.3. Series/Parallel Connections

Toincreasebothvoltageandcapacity,connectadditionalbatteriesinseriesandparallel.RefertoDiagram 3forseries/parallelconnections.

Diagram 3

2.5. Battery Orientation

Flooded/wetbatteriesmustbeplaceduprightatalltimes.Fluidinthebatterywillspillifthebatteryisplacedonitssideoratanangle.GelorAGMbatteriesarespill-proofsotheycanbeplacedeitheruprightoronitsside.

2.4. Connecting Batteries to Increase System Power

2.4.1. Series Connections

Toincreasevoltage,connectbatteriesinseries.Thiswillnotincreasethesystemcapacity.RefertoDiagram 1forseriesconnections.

Diagram 1

2.4.2. Parallel Connections

Toincreasecapacity,connectbatteriesinparallel.Thiswillnotincreasethesystemvoltage.RefertoDiagram 2forparallelconnections.

Diagram 2

Example :TwoT-105,6VBatteriesratedat225AHConnectedinSeriesSystemVoltage:6V+6V=12VSystemCapacity=225AH

Example :TwoT-105,6VBatteriesratedat225AHConnectedinParallelSystemVoltage:6VSystemCapacity=225AH+225AH=450AH

Example :FourT-105,6VBatteriesratedat225AHConnectedinSeries/ParallelSystemVoltage:6V+6V=12VSystemCapacity=225AH+225AH=450AH

TROJAN BATTERY USERS GUIDE

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Iftheelectrolytelevelisbarelycoveringtheplates,adddistilledorde-ionizedwatertoalevel1/8(3mm)belowtheventwell(thisistheplasticshieldinsidetheventhole)forstandardbatteriesandtothemaximum(MAX)levelindicatorforPlusSeriesbatteries

Afteraddingwater,secureventcapsbackonbatteries Tapwatermaybeusedifthelevelsofimpuritiesarewithinacceptablelimits.Referto

Table 3 forWaterImpurityLimits

Table 3

Recommended Maximum Allowable ImpuritiesIn Water for Battery Use

Impurity Parts Per Million Effects of Impurity

Color Clear and White -

Suspended Matter Trace -

Total Solids 100.00 -

Organic and Volatile Matter 50.0 Corrosion of positive plate

Ammonia 8.0 Slight self-discharge of both plates

Antimony 5.0 Self-discharge by local action, reduces life, lower on-charge voltage

Arsenic 0.5 Self-discharge, can form poisonous gas at negative

Calcium 40.0 Increase of pos