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Summary of Contents for Fullriver Battery DC Series
- Page 1 INSTALLATION AND OPERATION MANUAL...
- Page 2 FULLRIVER BATTERY prior written consent from Fullriver Battery. Fullriver Battery is not liable for direct, indirect, 3823 M ission special, exemplary, incidental or consequential , Ca 93012...
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Page 3: Table Of Contents
Table of Contents GETTING STARTED ..........2 1.1 - Safety 1.2 - Equipment checklist INSTALLATION . - Page 4 Notes age d...
- Page 5 INSTALLATION AND OPERATION MANUAL...
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Page 6: Getting Started
Getting Started Before installing your Fullriver battery, please adhere to the following safety guidelines and make sure that you have the proper equipment for installation, operation, and diagnostic testing. 1.1 - SAFETY PROTECT YOURSELF AND PROTECT YOUR BATTERY • Wear protective gear, including gloves, when handling a battery. • Install and remove a battery using the lifting handles provided. • Use a wrench with a rubber coated handle for installing, tightening, or removing battery connections. • Do not place any objects on top of a battery. • Do not smoke near a battery. •... -
Page 7: Installation
Installation Proper battery installation is the first step in getting the best performance out of your Fullriver battery. 2.1 - SELECTING THE APPROPRIATE CABLE SIZE Cables must be sized to carry the maximum expected load. Under-sized cables can result in over-heating, melted connections and are a potential fire hazard. Refer to TABLE 1 below for the current carrying capacity by cable size. These values are for cable lengths of 6 feet (1.83 meters) or less. It is preferable that all cables in a series connection or in a parallel connection are the same length. -
Page 8: Terminal Connections
Installation 2.2 - TERMINAL CONNECTIONS Terminal connections must be tightened using the correct torque values as defined in TABLE 2 below. Over or under tightened connections can result in terminal breakage, over-heating and/or meltdown. Using the proper torque value will provide optimum conductivity. To avoid a short circuit, use a wrench with an insulated or rubber coated handle when making terminal connections. See DIAGRAM 1 below for proper washer placement. TERMINAL TORQUE SPECS Terminal Type ft-lbs lbs-in Terminal Type ft-lbs lbs-in M6, AP 4.1-5.8 50-70 5.6-7.9 M10M (Stud) 7.7-9.6 92-115 10.4-13 7.1-7.9 85-95 9.6-10.7 3/8”... -
Page 9: Battery Orientation
Installation 2.3 - BATTERY ORIENTATION The ideal placement of batteries is upright. AGM and Gel batteries can be placed on their side if necessary. It is preferred that all the batteries within a pack be placed in the same orientation. NEVER place batteries in an inverted orientation (terminals pointed towards ground). 2.4 - SERIES CONNECTIONS There is more than one option to meet your voltage requirements. For example, for a 12 volt system, you may use one (1) 12 volt battery or two (2) 6 volt batteries wired in a series to make up the 12 volts. You may use as many batteries as you need to make up the system voltage. Connect the positive of one battery to the negative of the next through the entire string. See DIAGRAM 2 below for the proper series connection. -
Page 10: Parallel Connections
Installation 2.5 - PARALLEL CONNECTIONS There is more than one option to meet your energy requirements. For example, to meet the requirements for a 210 Amp-Hour system, you may use one (1) 210 Amp-Hour battery or two (2) 105 Amp-Hour batteries wired in parallel to make up the 210 Amp-Hours. Connect all the positive terminals together and all the negative terminals together in the string. See DIAGRAM 3 below for proper parallel connection. Parallel Connection: Capacity is increased in a parallel connection Two 12V, 105AH batteries = 12V, 210AH DIAGRAM 3 2.6 - SERIES / PARALLEL CONNECTIONS... -
Page 11: Cross Tying Batteries In Parallel Packs
Installation 2.7 - CROSS TYING BATTERIES IN PARALLEL PACKS In order to maintain balance in parallel battery packs, it is best to cross tie the batteries. This method of connection will maximize the performance and life of your battery system. Cross-tying batteries means connecting positive to positives and negatives to negatives of each adjacent battery in the set. See DIAGRAM 5 below for proper cross tying connections. The dotted lines represent the cross tied cables. DIAGRAM 5 Leave some space between batteries for airflow and minor battery expansion. 2.8 - CHARGING BATTERIES BEFORE USE New AGM or Gel batteries that have only been stored up to six months will not need to be charged prior to being put into service. If new AGM or Gel batteries have been stored for more than six months, and/or in an exceptionally hot environment, a charge may be necessary prior to being put into service. Also, if the batteries are not charged prior to being put into service, you may experience a slight reduction in range on the first cycle. Battery Nominal Voltage Open Circuit Voltage (O.C.V.) 2 Volt <... -
Page 12: Operation
Operation The performance and life of a battery will vary with the application, usage, temperature and depth of discharge. AGM and Gel batteries tend to deliver a higher capacity than rated (up to 10-15% higher) until they are broken in (approximately 30 cycles) and settle at their rated capacity. 3.1 - TEMPERATURE EFFECTS ON BATTERY PERFORMANCE AND LIFE Operating batteries above 80°F (27°C) will yield runtimes above the rated capacity while operating batteries below 80°F (27°C) will yield runtimes below the rated capacity. Cold temperatures can significantly reduce battery capacity (as shown in the chart below). Although higher temperatures increase the battery capacity, they also accelerate corrosion and reduce overall battery life. For example, batteries operating continuously at 100°F (37.8°C), could experience as much as a 25% reduction in life. 3.2 - OPERATING TEMPERATURE RANGE Recommended Maximum 5°F to 104°F -40°F to 160°F (-15°C to 40°C) (-40°C to 71°C) -
Page 13: Low Discharge Rate Effects
Operation 3.3 - LOW DISCHARGE RATE EFFECTS Battery cycle life will be reduced when the constant load applied in a cyclic application is at or below 0.7% of the total Ah in the battery bank (C20 rating). This is due to a higher rate of sulfation occuring in the middle of the plate that will cause a reduction in available capacity which in turns increases the depth of discharge over time. An effort to either increase the load above 0.7% of C20 and/or reduce the size of the battery bank’s capacity so the load is above 0.7% of C20 should be put forth if possible. 3.4 - DEPTH OF DISCHARGE VS. BATTERY LIFE Battery cycle life will vary significantly depending on the depth of discharge. The deeper the depth of discharge, the fewer the cycles a battery will deliver. Conversely, the shallower the depth of discharge, the more cycles a battery will deliver (as shown in the chart below). CYCLE LIFE vs DEPTH of DISCHARGE (DOD) *(Based on BCI Testing @ 2-hr Rate) 100% 1000 1500 2000 2500 3000 3500... -
Page 14: Charging
Charging Using the proper charger is critical to the performance and life of your AGM or Gel battery. If you are not sure if you have the right charger for AGM or Gel batteries, please call our technical support line at (800) 522-8191 or email help@ fullriverbattery.com for verification. 4.1 - CHARGER INSPECTION 1. The charger cable should be insulated and free of breaks or cuts. 2. The cable connectors should be clean and properly mated with the battery terminals to ensure a snug connection. 3. The charger’s AC cord should be free of breaks or cuts and the wall plug should be clean. 4.2 - CHARGING YOUR BATTERIES 1. Use an AGM charger or setting whenever available for AGM batteries. Use a Gel charger or setting whenever available for Gel batteries. -
Page 15: Current
Charging 4.4.1 - CURRENT All Models (excl. FSG): The recommended bulk current is 20-25% of the 20 Hr AH capacity or 0.20 x C20 (20 Hr. capacity in AH). The maximum allowable bulk current is 35% of the 20 Hr. AH capacity or 0.35 x C20 (20Hr. capacity in AH), unless specified. Example: DC115-12 is rated at 115AH @ 20 Hrs. The recommended bulk current is 0.20 x 115 = 23 Amps The maximum bulk current is 0.35 x 115 = 40 Amps FSG Series: The recommended bulk current is 12.5% of the 10 Hr. AH capacity or 0.125 x C10 (10 Hr. capacity in AH). The maximum allowable bulk current is 15% of the 10 Hr. AH capacity or 0.15 x C10 (10Hr. capacity in AH), unless otherwise stated. -
Page 16: Storage
Storage AGM and Gel batteries have a much longer shelf life than wet, lead-acid batteries. With a self-discharge of only 1-3% per month, AGM and Gel batteries can be stored for a year or longer without needing to be charged. 5.1 - BATTERY STORAGE PROCEDURE 1. Charge batteries before they are placed in storage. 2. Disconnect batteries from the equipment and charger to eliminate any parasitic loads. 3. Check the batteries based on conditions and schedule in TABLE 9 below. Temperature Time Below 68°F (20°C) 9 months 68°F to 86°F (20°C to 30°C) 6 months Above 86°F (30°C) 3 months TABLE 9 4. -
Page 17: Storage Temperature Range
Storage 5.2 - TEMPERATURE EFFECTS ON SELF-STORAGE If the storage environment is hot, batteries will self-discharge faster than in a cold environment as shown in the chart below. The FSG series will discharge approximately 40-60% slower above 86°F than the chart below indicates. Batteries CAN be safely stored on concrete floors without any negative effects. Concrete floors DO NOT drain batteries. 5.3 - STORAGE TEMPERATURE RANGE Recommended Maximum 5°F to 122°F (-15°C to 50°C) -40°F to 160°F (40°C to 71°C) TABLE 11 Store batteries in a cool, dry environment to minimize self discharge. -
Page 18: Testing
Testing Testing batteries can be complex and there are many application specific variables that cannot be considered in one simple test. This section is a guide to help you determine the overall condition of your batteries. Contact your local Fullriver Battery distributor for assistance. 6.1 - TEST PREPARATION 1. Check that the battery cables are in good working condition. Replace any damaged or broken cables. 2. Check that all terminal connections are tightened to proper torque specification as described in TABLE 2. 3. Fully charge batteries. 4. Let batteries rest for at least 8 hours once charging is complete. 6.2 - OPEN CIRCUIT VOLTAGE TEST 1. Check and record open circuit voltage (O.C.V.) of each battery. 2. -
Page 19: Optional Test
After completing SECTION 6.1 and SECTION 6.2, follow these steps: 1. Operate the vehicle/equipment until battery performance decreases. 2. Record voltages during and after operation. 3. Record time and distance of operation. 4. Provide the voltage, time, and distance data to a Fullriver Battery distributor or to Fullriver Battery technical support at (800) 522-8191 or email help@fullriverbattery.com. 5. This data will be analyzed in comparison to what is expected of the vehicle/equipment. 6.5 - CCA TEST (only applicable to Full Throttle series batteries) 1. -
Page 20: Battery Replacement Instructions
Testing & Your Clean-Green Energy Solution 6.6 - BATTERY REPLACEMENT INSTRUCTIONS As long as it is safe to do so, charge the set of batteries before replacing the failed ones to make sure the good batteries are fully charged. If possible, replace failed batteries with good batteries around the same age from another piece of equipment. Try to avoid mixing new batteries in equipment with old batteries. Put all new batteries in the same piece of equipment. 7.1 - FULLRIVER PRODUCTS Fullriver Battery produces sealed, maintenance-free batteries that are non- hazardous, non-spillable. During normal operation, our batteries will not release any harmful gases and will not leak any acidic electrolyte into the environment. Fullriver batteries are classified as safe for air, sea, and ground transportation. They meet all requirements of the International Air Transport Association (I.A.T.A.), the International Civil Aviation Organization (I.C.A.O.), the International Maritime Dangerous Goods (I.M.D.G.), and the Department of Transportation (D.O.T.). -
Page 21: Your Clean-Green Energy Solution
Your Clean-Green Energy Solution 7.3.2 - ABSORPTION SETTINGS Absorption time varies per installation according to total bank size and total PV kW. Our maximum absorption time is 4 hours, however most installations need 2-3 hours on average. To estimate your rough absorption time, use the following formu- [(AH * DOD) / CHARGE AMPS * 0.85] If your charge controller offers a setting such as Absorb End Amps (Outback) or sim- ilar that automatically transfers to float charge based on amps accepted, absorption time should be set to 4 hours and this setting should be set to approximately 1.75% of total bank capacity in Ah. 7.3.3 - CHARGE RATE &... -
Page 22: Transportation Information
Transportation Information Fullriver DC, Full Force, and Full Throttle batteries are sealed lead-acid batteries made with Absorbent Glass Mat (AGM) technology. The electrolyte is absorbed into the fiberglass separator material rather than in a free-flowing liquid form. Fullriver DCG and FSG batteries are sealed lead-acid batteries made with gelled electrolyte technology. The electrolyte is suspended in a thixotropic gel applied to the plates rather than in a free-flowing liquid form. Fullriver batteries are non-spillable electric storage batteries. They are exempt from the requirements of DOT’s hazardous materials regulations since they adhere to the requirements of code 49 CFR Section 173.159(D), which states: A non-spillable, wet, electric storage battery is exempt from all other requirements of this sub-chapter under the following conditions: • The battery must be protected against short circuits and securely packaged •... -
Page 23: Appendix
Appendix A.1 - TEMPERATURE RANGES Condition Recommended Maximum Storage 5°F to 122°F (-15°C to 50°C) -40°F to 160°F (-40°C to 71°C) Operation 5°F to 104°F (-15°C to 40°C) -40°F to 160°F (-40°C to 71°C) Charge with TC 5°F to 122°F (-15°C to 50°C) -40°F to 160°F (-40°C to 71°C) Charge w/o TC 32°F to 104°F (0°C to 40°C)
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