TROJAN AES AGM Battery Highlights New AES Battery User Guide

TROJAN **AES AGM Battery Highlights New AES Battery User Guide

**

CONGRATULATIONS

on your purchase from Trojan Battery Company, the manufacturer of the world’s most trusted deep-cycle batteries. The battery you purchased was engineered by Trojan to deliver superior power, performance, durability, and reliability for use in a broad range of demanding applications. Our goal is to provide reliable energy storage solutions that enhance the way people live and work around the world.

TROJAN BATTERY COMPANY WITH QUALITY SYSTEM CERTIFIED BY DNV
= ISO 9001: 2015 =

THIS USER’S GUIDE

was created by Trojan’s application engineers and contains vital information regarding proper care and maintenance of your new battery. Please read through this User’s Guide carefully and completely before using your battery. It will help you achieve optimum performance and long life from your new investment.

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.

battery without securing vent caps on the cells
Always wear protective clothing, gloves, and safety goggles| Never smoke near batteries
Always use insulated tools when working on batteries| Never wear jewelry or other metal objects when working on or around batteries
Always check connections for proper torque| Never make direct contact with the electrolyte (sulfuric acid). If this occurs, flush with large amounts of water.
Always keep sparks and flames away from batteries| Never place objects on top of batteries
Always use short cables of appropriate size to minimize voltage drop| Never add acid to a battery
Always ensure plates are covered in water before charging| Never charge a frozen battery
Always make sure charger is set for the appropriate battery type (flooded, AES / AGM or gel)| Never charge a battery when the temperature is above 122°F (50°C)
Always charge batteries before installing| Never store batteries unless they are fully charged
Always neutralize small spills with baking soda and water. For large spills, contact the appropriate first responders.| Never leave an acid spill unattended

WARNING! Risk of fire, explosion, or burns. Do not disassemble, heat above 158°F (70°C), or incinerate.

EQUIPMENT NEEDED

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

• Proper personal protective equipment (eye protection and acid resistant gloves)
• Distilled or deionized water
• Insulated tools
• Baking soda
• Terminal protector spray
• Voltmeter
• Hydrometer (flooded/wet batteries)
• Battery charger
• Discharge tester (if available)

BATTERY INSTALLATION

To ensure you install your batteries properly and safely, please use the following guidelines.
BATTERY CONNECTIONS
Battery cables provide the link between the batteries, equipment and charging system. Faulty connections can lead to poor performance, terminal damage, meltdown, or fire. To ensure proper connections, please use the following guidelines for cable size, torque values and terminal protection.
TERMINAL TYPES
Figure 1 illustrates various terminal types found on Trojan batteries. Refer to the appropriate terminal type when determining proper torque in Section 3.5.
FIGURE 1 – TERMINAL TYPES

| | | | | |
---|---|---|---|---|---|---

1        ELPT

| 2       EHPT| 3       EAPT| 4                     EUT| 5          LT| 6 DT|

7         UT

Embedded Low Profile

| Embedded High Profile| Embedded Auto Post| Embedded Universal| L-Terminal| Automotive Post & Stud|

Universal

| | | | | |
---|---|---|---|---|---|---
8 AP| 9 WNT| 10 DWN| 11 ST| 14 IND| 15 M6/M8|
Automotive
Post| Wingnut| Dual Wingut| Stud| Industrial| 6mm/8mm
Insert|

CORRECT HARDWARE INSTALLATION
If using flat washers, it is very important to ensure the battery cable lug is contacting the lead surface of the terminal, and the washer is placed on top of the lug. Do not place a washer between the battery terminal and the lug, as this will create high resistance and cause excessive heating of the connection and terminal. It is important that fasteners be tightened to the appropriate torque for each terminal type, as defined in Table 2.

FIGURE 2

Flooded Battery Terminal Configurations

ELPT
|

Nut – Torque to 95-105 (in-lbs), 11-12 (Nm)
**Washer*
Cable Lug
Terminal **

| EUT
| Cable Lug
Nut – Torque to 95-105 (in-lbs), 11-12 (Nm)
Washer
Terminal
Bolt
EHPT
| Nut – Torque to 95-105 (in-lbs), 11-12 (Nm)
Washer
Cable Lug
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 Connector
Torque to 50-70 (in-lbs), 6-8 (Nm)
Stud Terminal**|

LT

| Nut – Torque to 95-105 (in-lbs), 11-12 (Nm)
**Washer*
Cable Lug
Bolt
Terminal**

IND

| Cable Lug
Nut – Torque to 100-120 (in-lbs), 11-14 (Nm)
**Washer*
Bolt
Terminal**|

|

Images shown reflect correct hardware placement. All hardware supplied for AGM with C-max and AES models, motive and solar.
*Hardware not supplied by Trojan Battery Company.

FIGURE 3

AES / AGM Battery Terminal Configurations

Flooded Battery Terminal Configurations

LT
Lock Washer

| Nut – Torque to 70 (in-lbs), 6-8 (Nm)
Washer
Cable L
Bolt – 20 mm
M8 Terminal
Bolt – 16mm – Torque to 85-95 (in-lbs), 10-11 (Nm)
Lock Washer
LT Adapter|

DT

| Nut Torque to 95-105 (in-lbs), 11-12 (Nm)
Cable Lug
Lock Washer
AP Terminal
AP Connector Torque to 50-70 (in-lbs), 6-8 (Nm)
Washer
Stud Terminal

M6†

| Lock Washer
Bolt – Torque to 25-35 (in-lbs), 3-4 (Nm)
Washer
Cable Lug
Terminal|

M8

| Lock Washer
Bolt Torque to 85-95 (in-lbs), 10-11 (Nm)
Washer
Cable Lug
Terminal
AP (MOTIVE AES / AGM WITH C-MAX)
| 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
| Nut Torque to 120-180 (in-lbs), 14-20 (Nm)
Cable Lug
Terminal|  |

Images shown reflect correct hardware placement. All hardware supplied for AGM with C-max and AES models, motive and solar.
†Discontinued

Gel Battery Terminal Configurations

LT

| **Washer*
Nut – Torque to 95-105 (in-lbs), 11-12 (Nm)
Terminal
Cable Lug
Bolt**|

UT

| Nut Torque to 95-105 (in-lbs), 11-12 (Nm) –
*Cable Lug
Washer
Terminal Bolt**
---|---|---|---

DT

| Nut Torque to 95-105 (in-lbs), 11-12 (Nm) Cable Lug
*Washer AP**

Terminal
AP Connector
Torque to 50-70 (in-lbs), 6-8 (Nm)

Stud Terminal

|

AP

| AP Connector
Torque to 50-70 (in-lbs), 6-8 (Nm)
Terminal

Images shown reflect correct hardware placement. All hardware supplied for AGM with C-max and AES models, motive and solar.
**Hardware not supplied by Trojan Battery Company

CABLE SIZE
Battery cables should be sized to handle the expected load. Refer to Table 1 for the maximum amperage based on the
cable/wire gauge size.

TABLE 1

Table values are from NEC Table 310.15(B)16 for copper cables rated at 167°F (75°C), operating at an ambient temperature of no more than 86°F (30°C). Lengths in excess of 6 feet (1829 mm) may require heavier gauge wire to avoid unacceptable voltage drop. 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 Electrical Code for correct cable/wire size, which can be located at www.nfpa.org.

TORQUE VALUES
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.

Flooded
DWNT, ELPT, EUT, LT, UT, WNT| 95 – 105| 11 – 12
EAPT, AP| 50 – 70| 6 – 8
DT, EHPT| 50 – 70 (AP Connector)95 – 105 (Stud Portion)| 6 – 8 (AP Connector)11-12 (Stud Portion)
IND| 100 – 120| 11 – 14
AES / AGM
M8| 85 – 95| 10 – 11
AP (Adapter) Motive AES / AGM with C-Max| 50 – 70 (AP Connector)95 – 105 (AP Adapter)| 6 – 7 (AP Connector)11 – 12 (AP Adapter)
AP| 44 – 62| 5 – 7
DT| 50 – 70 (AP Connector)95 – 105 (Stud Portion)| 6 – 8 (AP Connector)11-12 (Stud Portion)
LT (Adapter)| 55 – 70 (Nut)85 – 95 (Bolt)| 6 – 8 (Nut)10 – 11 (Bolt)
M6| 25 -35| 3 – 4
ST| 120 – 180| 14 – 20
Gel
AP| 50 – 70| 6 – 8
LT, UT| 95 – 105| 11 – 12
DT| 50 – 70 (AP Connector)95 – 105 (Stud Portion)| 6 – 8 (AP Connector)11-12 (Stud Portion)

WARNING! Use an insulated wrench when making battery connections.

TERMINAL PROTECTION
Corrosion can build up on terminals if they are not kept clean and dry. To prevent corrosion, after tightening the
fasteners, apply a thin coat of terminal protector spray that can be purchased through your local battery dealer.
CONNECTING BATTERIES IN BANKS
You can increase capacity and voltage, or both, by configuring your batteries as shown in Table 3.

| SERIES CONNECTION| PARALLEL CONNECTION| SERIES/PARALLEL **CONNECTION
---|---|---|---
**| |
| | Note: maximum of three parallel strings
To increase voltage, connect batteries in series. This will not increase the system capacity.| To increase capacity, connect batteries in parallel. This will not increase the system voltage.| ** To increase both voltage and capacity, connect additional batteries in series and parallel.
EXAMPLE| ** Two T-105, 6V Batteries rated at 225Ah Connected in Series| Two T-105, 6V Batteries rated at 225Ah Connected in Parallel| Four T-105, 6V Batteries rated at 225Ah Connected in Series/Parallel
System Voltage = 6V + 6V = 12V System Capacity = 225Ah| System Voltage = 6VSystem Capacity = 225Ah + 225Ah = 450Ah| ** System Voltage 6V + 6V = 12VSystem Capacity = 225Ah + 225Ah = 450Ah
| CALL TECH SUPPORT FOR ADDITIONAL CONFIGURATIONS**

VENTILATION
Deep-cycle flooded/wet lead acid batteries release small amounts of gas during usage, particularly during the charging process. Deep-cycle AES / 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 battery- specific information helpful in determining ventilation needs, please contact Trojan Battery Company’s technical support engineers.

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.
AES / AGM and gel batteries can be placed in a standard vertical (terminals on top) or optional horizontal (terminals in front) orientation. If placed in a horizontal orientation, the batteries should be placed on their long sides and NOT their short ends.
Figure 4

shows the two acceptable AES / AGM / gel battery orientations. The battery on the top shows the correct horizontal orientation, while the one below is the vertical orientation. Note that these batteries cannot be installed upside down.

BATTERY ENVIRONMENT
Batteries should be stored and installed in a clean, cool and dry place, keeping water, oil, and dirt away from the batteries. If any of these materials are allowed to accumulate on the batteries, tracking and current leakage can occur, resulting in self-discharge and possible short-circuits. Battery chargers should also be  installed in well-ventilated, clean areas that are easily accessible. Relative humidity should be <90%.

TEMPERATURE
The recommended operating temperature range for Signature, Solar Signature, Solar Premium, and gel batteries is -4°F to 113°F (-20°C to 45°C). The recommended operating temperature range for Solar Industrial and AGM batteries is -4°F to 122°F (-20°C to 50°C). Note that battery life diminishes as temperature increases, while capacity increases with temperature. The recommended operating temperature range for Solar and Motive AES batteries is -40°F to 140°F (-40°C to 60°C) for discharge and -10°F to 140°F (-23°C to 60°C) for charge.
It is important to minimize temperature variations between the cells. Therefore, avoid restricting airflow by tightly packing batteries together. The batteries should have a minimum of 0.50” (12.7 mm) of space between them to  allow for adequate airflow.

PREVENTIVE MAINTENANCE

INSPECTION

• Examine the outside appearance of the battery. The tops of the batteries and terminal connections should be clean, dry, and free of corrosion. Refer to Section 4.3, Cleaning.
• If fluids are present on the top of a deep-cycle flooded/wet battery, it may mean that the battery is being overwatered or overcharged. Refer to Section 4.2, Watering, for the proper watering procedure.
• If fluid is present on the top of a deep-cycle AES / AGM or gel battery, it may mean that the battery is being overcharged, which can reduce battery performance and life.
• Check battery cables and connections. Replace any damaged cables and tighten any loose connections. Refer to Section 3.5, Torque Values.

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 AES / AGM or gel batteries.

• Use only distilled or deionized water. Tap water can contain contaminants that will damage the battery. Also, be aware that water can pick up impurities from containers, piping, and fixtures. Table 4 contains the limits for impurities to avoid damaging batteries.
• 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.
• Check the electrolyte levels by removing the vent caps and placing them upside down so that dirt does not accumulate on the underside of the cap. For Plus Series™ batteries, simply flip open the cap.
• If the electrolyte level is barely covering the plates, add distilled or deionized water to the proper level as illustrated in Figure 5.
  
  Standard Vent Wellu

Vent Well with Level Indicator

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

TABLE 4

WATER IMPURITY LIMITS

Impurity| Parts Per Million| Effects of Impurity
Color| Clear and “White”| –
Suspended Matter| Trace| –
Total Solids| 100| –
Organic and Volatile Matter| 50| Corrosion of positive plate
Ammonia| 8.0| Slight self-discharge of both plates
Antimony| 5.0| Increased self-discharge, reduces life, lower on-charge voltage
Arsenic| 0.50| Self-discharge, can form poisonous gas at negative plate
Calcium| 40| Increase of positive plate shedding
Chloride| 5.0| Loss of capacity in both plates, greater loss on the positive plate
Copper| 5.0| Increased self-discharge, lower on-charge voltage
Iron| 3.0| Increased self-discharge at both plates, lower on-charge voltage
Magnesium| 40| Reduced life
Nickel| None Allowed| Substantial lowering of on-charge voltage
Nitrates| 10| Increased sulfation on the negative plate
Nitrites| 5.0| Corrosion of both plates, loss of capacity, reduced life
Platinum| None Allowed| Increased self-discharge, lower on-charge voltage
Selenium| 2.0| Positive plate shedding
Zinc| 4.0| Slight self-discharge of negative plate

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.
• For flooded batteries, check that all vent caps are secured properly on the battery.
• Clean the top of the battery, terminals, and connections with a cloth or non-metallic brush, and a solution of baking soda and water comprised of 1 cup of baking soda to 1 gallon of water (60 ml of baking soda per liter of water). Do not allow cleaning solution to get inside the battery.
• Rinse with water and dry with a clean cloth.
• Apply a thin coat of terminal protector spray which can be purchased through your local battery dealer.
• Keep the area around batteries clean and dry.

CHARGING & EQUALIZING

INITIAL CHARGING
Due to the potential for self-discharge during shipping and storage, batteries should be given a full charge prior to first use. See the next section for details on proper charging.

NORMAL 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.

• Charge only in well-ventilated areas.

• Batteries should be fully charged after each use. “Use” is defined as 30 minutes or more of runtime.

• Before charging, make sure the charger is set to the appropriate program for deep cycle flooded/wet, AES / AGM, or gel batteries.

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

• Lead-acid batteries do not have a memory effect and should not be fully discharged prior to charging.

• Temperature compensated charging is desirable for all batteries, but should always be used with AES / AGM and gel batteries. Temperature compensation coefficients raise the voltage/cell for temperatures below 77°F (25°C), and lower the voltage/cell for temperatures above 77°F (25°C).

• Never charge a frozen battery.

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

• CHARGING FLOODED BATTERIES

• Prior to charging, check electrolyte levels to verify that the plates are covered with electrolyte. If plates are
  exposed, add enough water (distilled or deionized) to just cover the plates prior to charging.

• Make sure that vent caps are in place and are properly secured.

• Trojan recommends a 3-phase I-V-I profile for charging its flooded batteries

  • Phase 1: Constant current bulk charge
    A constant current equal to 10-13% of C20 is applied as the voltage slowly increases.
    The bulk phase ends when the voltage rises to the absorption voltage.

  • Phase 2: Constant voltage absorption charge
    A constant voltage equal to 2.35-2.45 V/cell is applied as the current slowly declines.
    The absorption phase ends when the current falls to the finish current.

  • Phase 3: Constant current finish charge
    A constant current equal to 1-3% of C20 is applied as the voltage increases. The finish phase ends when
    the battery is fully charged. Flooded batteries will gas (bubble) toward the end of the finish phase to ensure proper mixing of electrolyte.

  • Refer to Table 5 and Figure 6 for system charging parameters and typical voltage and current profiles.

  • In applications where batteries are infrequently used, it is desirable to compensate for self-discharge by keeping
    a low charging voltage on the batteries. This is called the float voltage. Avoid using continuous float charging on flooded batteries that are charged more than once/week. When float charging is used, it is started immediately after the end of the finish stage.

• Following charge completion, add water if required as directed in Section 4.2.

TABLE 5

FLOODED/WET BATTERIES – NORMAL CHARGING PARAMETERS @ 25°C (77°F)

* Trojan Battery Line| Maximum Charge Current (% of C20)| Absorption Voltage (V/cell)| Maximum Absorption Phase Time (hours)| Finish Current (% of C20)| Equalization Voltage(V/cell)| Float Voltage (V/cell)| Temperature Compensation (V/cell)
**** Solar Premium andSignature| **** 13%| **** 2.45| **** 4| **** 1-3%| **** 2.70| **** 2.25| Fahrenheit:-2.8 mV x(Tbattery-77)Celsius:-5 mV x (Tbattery-25)

• If charging time is limited contact Trojan Technical Support for assistance.
• In cases where the charger has a bulk voltage setting rather than a current, use the above absorption settings.

FIGURE 6

Recommended Deep-Cycle Flooded/Wet Charging Profile

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

CHARGING VALVE-REGULATED LEAD ACID (VRLA) BATTERIES (AES / AGM / GEL)
There are various ways to charge VRLA batteries. For optimum performance and life, Trojan recommends the following:

• Use a 2-phase I-V profile

• Phase 1: Constant current bulk charge
  A constant current equal to a percentage of C20 is applied as the voltage slowly increases.
  The recommended currents are as follows:

  • AES: Up to 50% of C20
  • AGM: 20% of C2
  • Gel: 10-13% of C20
    The bulk phase ends when the voltage rises to the absorption voltage.

• Phase 2: Constant voltage absorption charge
  A constant voltage equal to 2.35-2.45 V/cell is applied as the current slowly declines. The absorption phase
  ends when the current stabilizes at a low value of approximately 0.005 x C20.

• Refer to Table 6 as well as Figure 7 and Figure 8 for system charging parameters and typical voltage and current profiles

• In applications where batteries are infrequently used, it is desirable to compensate for self-discharge by keeping a low charging voltage on the batteries. This is called the float voltage. Avoid using continuous float charging on VRLA batteries that are charged more than once/month. When float charging is used, it is started immediately after the end of the finish stage.

• VRLA charging voltages should always be temperature compensated per Table 6.

TABLE 6

Valve Regulated Batteries – Normal Charging Parameters @ 77°F (25°C)

* Trojan Battery Line| Maximum Charge Current (% of C20)| ** Absorption Voltage (V/cell)| Maximum Absorption Phase Time (hours)| ** Finish Current (% of C20)| Equalization Voltage(V/cell)| Float Voltage (V/cell)| Temperature Compensation (V/cell)
AES| 50%| 2.40| 2| –| N/A| 2.25| **** Fahrenheit:-2.8 mV x(Tbattery-77)Celsius:-5 mV x (Tbattery-25)
AGM| 20%
Gel| 13%

• If charging time is limited, contact Trojan Technical Support for assistance.
• In cases where the charger has a bulk voltage setting rather than a current, use the above absorption settings.

Recommended Trojan Deep-Cycle AES / AGM Charging Profile

FIGURE 8

EQUALIZING (FLOODED/WET BATTERIES ONLY)
When batteries are used in a battery bank, over time some of the batteries can drift to a lower state of charge than others. This charge imbalance can lead to sulfation and premature battery failure.
In order to ensure that these charge imbalances are corrected, a process called “equalization” is used. Equalizing is an overcharge performed after fully charging deep-cycle flooded/wet batteries. An equalizing charge prevents electrolyte stratification and reduces sulfation, which are leading causes of battery failure. Trojan recommends equalizing for 2-4 hours in the following situations:

• Periodically (every 30 days)
• When batteries have a low specific gravity after charging (<1.235), or
• When the range of specific gravities between cells is > 0.030 points
• Reference Section 9.3 for instructions on specific gravity measurement.

WARNING! Deep-cycle AES / 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.
• Measure the specific gravity every hour.
• Discontinue the equalization charge when the specific gravity no longer rises.

STORAGE

The following tips will help ensure that your batteries emerge from storage in good condition:

• Charge batteries before placing them in storage.
• Store in a cool and 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 open-circuit voltage of flooded batteries every 4 – 6 weeks. Monitor the open circuit voltage for AES / AGM or gel batteries every 2 – 3 months.
• Batteries in storage should be charged when they decline to the following state of charge (SOC):
  • Flooded batteries: 70% SOC
  • AES / AGM/ gel batteries: 75% SOC
• Refer to Table 7 for the relationship between SOC, specific gravity (flooded only) and open-circuit voltage. If charging is needed, follow the normal charging procedure outlined in Section 5.2.
• When batteries are taken out of storage they should be given an initial charge as outlined in Section 5 prior to use.

STORAGE IN HOT ENVIRONMENTS
Storage in hot environments (greater than 90°F or 32°C) can negatively impact batteries. Avoid direct exposure toheat sources, if possible, during storage. Batteries self-discharge faster at high temperatures. If batteries are stored during hot summer months, monitor State-of-Charge on a regular basis as follows:

• Flooded batteries: check specific gravity or voltage every 2 – 4 weeks.
• AES / AGM or gel batteries: check voltage every 1 – 2 months.

Freezing Point of Electrolyte

Specific Gravity| Temperature
°C| °F
1.280| -68.9| -92.0
1.265| -57.4| -71.3
1.250| -52.2| -62.0
1.200| -26.7| -16.0
1.150| -15.0| -5.0
1.100| -7.2| 19
Source: BCI Service Manual © 1995

STORAGE IN COLD ENVIRONMENTS
If possible, avoid locations where freezing temperatures are expected during storage. Batteries can freeze in cold temperatures (less than 32°F or 0°C) if they are not fully charged. If batteries are stored during cold winter months, it is critical that they be kept at a high state of charge as outlined above.

TABLE 7

FLOODED/WET STATE OF CHARGE AS A FUNCTION OF SPECIFIC GRAVITY AND OPEN- CIRCUIT VOLTAGE

STATE OF CHARGE (%)| SPECIFIC GRAVITY| CELL| 6 VOLT| 8 VOLT| ** 12 VOLT
100| 1.277| 2.122| 6.37| 8.49| 12.73
90| 1.258| 2.103| 6.31| 8.41| 12.62
80| 1.238| 2.083| 6.25| 8.33| 12.50
70| 1.217| 2.062| 6.19| 8.25| 12.37
60| 1.195| 2.04| 6.12| 8.16| 12.24
50| 1.172| 2.017| 6.05| 8.07| 12.10
40| 1.148| 1.993| 5.98| 7.97| 11.96
30| 1.124| 1.969| 5.91| 7.88| 11.81
20| 1.098| 1.943| 5.83| 7.77| 11.66
10| 1.073| 1.918| 5.75| 7.67| 11.51
AES / AGM STATE OF CHARGE AS A FUNCTION OF OPEN-CIRCUIT VOLTAGE
STATE OF CHARGE (%)| ** SPECIFIC GRAVITY| CELL| 6 VOLT| 8 VOLT| 12 VOLT
100| 1.295| 2.14| 6.42| 8.56| 12.84
75| 1.245| 2.09| 6.27| 8.36| 12.54
50| 1.195| 2.04| 6.12| 8.16| 12.24
25| 1.145| 1.99| 5.97| 7.96| 11.94
0| 1.095| 1.94| 5.82| 7.76| 11.64
GEL STATE OF CHARGE AS A FUNCTION OF OPEN-CIRCUIT VOLTAGE
PERCENTAGE CHARGE| * SPECIFIC GRAVITY| ** CELL| 6 VOLT| 8 VOLT| **** 12 VOLT
100| 1.295| 2.14| 6.42| 8.56| 12.84
75| 1.265| 2.11| 6.33| 8.44| 12.66
50| 1.215| 2.06| 6.18| 8.24| 12.36
25| 1.155| 2.00| 6.00| 8.00| 12.00
0| 1.125| 1.97| 5.91| 7.88| 11.82

• Although the specific gravity cannot be measured in a VRLA battery, an approximate value can be useful in determining  the freezing point of electrolyte.

MAXIMIZING THE PERFORMANCE OF YOUR TROJAN BATTERY

• Follow all the procedures in this User’s Guide for proper installation, maintenance and storage.
• Do not discharge your battery to more than 80% depth of discharge. This safety factor will eliminate the chance of over-discharging and damaging your battery.
• If you have any questions or concerns about battery care, please contact Trojan Battery Company’s technical support engineers at 800-423-6569 Ext. 3045 or +1-562-236-3045 before a problem develops.

WHAT TO EXPECT FROM YOUR TROJAN BATTERY

• A new deep-cycle battery will not immediately deliver its full rated capacity. This is normal and should be expected since it takes time for a deep-cycle battery to reach peak capacity.
• Trojan’s deep-cycle AES / AGM and gel batteries will reach rated capacity in less than 20 cycles.
• Trojan’s deep-cycle flooded batteries take 50 – 100 cycles to achieve full, peak capacity.
• When operating batteries at temperatures below 80°F (27°C), they will deliver less than the rated capacity. For example at 0°F (-18°C) the battery will deliver 50% of its capacity and at 80°F (27°C) it will deliver 100% of its capacity.
• When operating batteries at temperatures above 80°F (27°C), they will deliver more than the rated capacity but battery life will be reduced.
• The life of a battery is difficult to predict and will vary by application, frequency of usage and level of maintenance.

FIGURE 9

FLOODED BATTERIES – CAPACITY VS. TEMPERATURE

Percent of Available Capacity
Note: Typical behavior at 5-Hr rate

ROUBLESHOOTING

These battery testing procedures are guidelines only for identifying a deep- cycle battery that may need to be replaced. Unique situations may be observed that are not identified within this procedure. Please contact Trojan Battery Company’s technical support engineers at 800-423-6569 Ext. 3045 or +1-562-236-3045 for help interpreting any test data.

PREPARATION FOR TESTING

• If applicable, 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 (60 ml of baking soda per liter 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 Torque Values Section 3.5.
• For deep-cycle flooded/wet batteries, check the electrolyte level and add water if necessary. Refer to Watering Section 4.2.
• Ensure batteries are fully charged before discharge testing to obtain accurate results.

VOLTAGE TESTING WHILE CHARGING

• Disconnect and reconnect DC plug to restart charger.
• While the batteries are charging, record the current in the last ½ hour of the 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 readings shown in Table 8, proceed to the step below to measure the on-charge voltages:

Table 8

System/Battery Voltage| 48V| 36V| 24V| 12V| 8V| 6V
End-of-Charge Threshold Voltage| 56V| 42V| 28V| 14V| 9.3V| 7V

• If the end-of-charge voltage does not exceed these values, 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.
• Compare each voltage to the proper entry in Table 9. If any battery is below the appropriate Minimum Voltage
  Threshold and the variation between all of the voltages is greater than the Allowable Variation, the low battery  may have failed.

TABLE 9

ON-CHARGE TEST THRESHOLDS

NOMINAL BATTERY VOLTAGE| MINIMUM VOLTAGE THRESHOLD| ALLOWABLE VARIATION WITHIN A SET
6V| 7V| 0.5V
8V| 9.3V| 0.7V
12V| 14V| 1.0V

SPECIFIC GRAVITY (FLOODED/WET BATTERIES ONLY)

• Use a reliable, high-quality hydrometer for specific gravity measurements.

• Fill and drain the hydrometer 2 – 3 times before drawing a sample from the battery.

• Measure specific gravity readings for all battery cells.
  Hydrometer

• Correct 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).

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

  • If any battery has a specific gravity variation of more than 0.030 between cells, equalize the set.
  • If there is still a significant variation, there may be a failed battery.

OPEN CIRCUIT VOLTAGE TESTING

• For accurate voltage readings, batteries must remain idle at least 6 hours, and preferably up to 24 hours.
• Measure and record the individual battery voltages.
• If any recorded voltage differs from another one by more than 0.3V, equalize the set (deep-cycle flooded/wet batteries ONLY). Refer to Section 5.3, Equalizing.
• Measure the individual battery voltages again.
• If any recorded voltage differs from another one by more than 0.3V, compared to any other battery in the set, you may have a failed battery.

DISCHARGE TESTING

• Follow the procedure below to determine battery capacity.

• Ensure the battery set has been fully recharged before testing.

• Prior to running a discharge test, ensure that all charging sources and loads are disconnected from the batteries.

• Connect and start discharger.

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

• Correct runtime minutes for temperature using one of the following formulas*.

  • For temperature measurements in Fahrenheit
    Mc = Mr [1 – 0.005 x (T1 – 80)]

  • For temperature measurements in Celsius
    Mc = Mr [1 – 0.009 (T1 – 27)] Where Mc = Corrected discharge time corrected to 80°F (or 27°C)
    Mr = Recorded discharge time
    T1 = Battery temperature at end of discharge (°F or°C)

• If the corrected discharge time is greater than 50% of the batteries’ rated capacity at that discharge rate, then battery performance is considered acceptable.

• Restart the discharger to record the individual battery voltages while still under load (current being drawn).

• If the discharge runtime is less than 50% of the batteries’ rated capacity, the battery with a voltage that is 0.5V lower than the highest voltage may be a failed battery.

  • There are other methods of testing batteries including internal resistance (i.e. C.C.A. testers) and carbon pile discharge testers. However, these are not suitable testing methods for deep-cycle batteries.

BATTERY RECYCLING

Lead acid batteries are the environmental success story of our time. Per the International Lead Association, in Europe and the USA, 99% of all battery lead is recycled. In fact, lead acid batteries top the list as the most highly recycled consumer products. Trojan Battery supports proper recycling of your battery to keep the environment clean.

Please contact your nearest Trojan Distributor, at www.trojanbattery.com, to learn how to properly recycle your batteries.

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

Recycling For A Better Environment
Transportation The same network that distributes new batteries also safely collects and returns used batteries for recycling.

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

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

Crush the case and covers

Plastic pellets

New Covers and Cases
New battery covers and cases are manufactured using recycled plastic pellets
** New cases and covers

Lead
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

Electrolyte: Option 1
** Sodium sulfate crystalsseparated from used electrolyte (dilute sulfuric acid) is recycled and sold for use in textiles, glass and detergent manufacturing
Neutralize electrolyte

Sodium sulfate crystals
|
Glass, textiles, detergent

Electrolyte: Option 2
** At some recyclers, usedelectrolyte is reclaimed and reused in manufacturing new batteries. At others, it is neutralized and managed according to federal and state water permits
Electrolyte is neutralized and sent to a water treatment plant
OR
** Electrolyte  is chemically treated and reused

New Battery

Graphics provided by Battery Council International

BATTERY ABBREVIATIONS

AGM : Absorbed Glass Mat
A : Ampere
Ah : Ampere-hour
AWG : American Wire Gauge
AP : Automotive Post Terminal
°C : Degrees Celsius
C.C.A. : Cold Cranking Amps
DOD Depth of Discharge
DT : Automotive Post & Stud Terminal
DWNT Dual Wingnut Terminal
EAPT Embedded Automotive Post Terminal
EHPT Embedded High Profile Terminal
ELPT Embedded Low Profile Terminal
EUT Embedded Universal Terminal
°F Degrees Fahrenheit
IND Industrial Terminal
LT L-Terminal
M6/M8 6mm/8mm terminal
Mc Minutes Corrected
Mr Minutes Recorded
SOC : State of Charge
ST : Stud Terminal
T   : Temperature
UT : Universal Terminal
V V : olt
WNT : Wingnut Terminal

TROJAN BATTERY COMPANY

would like to thank you for selecting our battery. With close to 100 years of experience, Trojan Battery is the world’s most trusted name in deep-cycle battery technology backed by our outstanding technical support. We look forward to serving your battery needs.

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 Trojan Battery Company, LLC.
Trojan Battery Company and the Trojan Battery logo are registered trademarks of Trojan Battery Company.
Trojan AES, T2 Technology, Maxguard T2 Separator, Alpha Plus Paste, HydroLink, Plus Series, Polyon, Smart Carbon™, and OverDrive AGM 31 are either registered trademarks or trademarks of Trojan Battery Company.
© 2023 Trojan Battery Company, LLC. All rights reserved. Trojan Battery Company is not liable for direct, indirect, special, exemplary, incidental or consequential damagesthat 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 notice or obligation.
2023005-Users-Guide-FLOODED-AES-AGM-GEL

References

• NFPA | The National Fire Protection Association
• Trojan Battery | Home

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