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US BATTERY US L16 XC2 User Manual

Deep cycle battery
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  • Page 1 DEEP CYCLE BATTERY USER MANUAL WWW.USBATTERY.COM...
  • Page 2 Corona, CA -Headquarters Evans, GA Augusta, GA Congratulations, on your purchase of U.S. Battery Mfg. Co., batteries. We are the manufacturer of the world’s most trusted deep-cycle lead-acid batteries. The batteries you purchased were created by U.S. Battery Manufacturing Company to deliver superior energy, performance, durability and reliability for use in a broad range of demanding applications.

  • Page 3: Table Of Contents

    CONTENTS 1 BEFORE YOU START 8.4 ON-CHARGE VOLTAGE TESTING 8.5 OPEN CIRCUIT VOLTAGE TESTING 1.1 SAFETY 1.2 EQUIPMENT NEEDED 9 ADDITIONAL INFORMATION 1.3 SAFETY DATA SHEETS (MSDS) 9.1 PRODUCT SPECIFICATION SHEETS 2 INSTALLATION 9.2 SHORT CIRCUIT CURRENT 9.3 DATE CODES 2.1 CABLE SIZE AND BOLT NUT SPECIFICATION 9.4 C-RATES 2.2 SPEEDCAPS™...

  • Page 4: Before You Start

    BEFORE YOU START The following Safety and Equipment sections are provided to ensure safe and success- ful battery installation and maintenance: 1.1 SAFETY Batteries can deliver an enormous amount of power that can result in injury and/or death, observing the following precautions is the difference between successful bat- tery maintenance/installation and a night in the emergency room: ●...

  • Page 5: Safety Data Sheets (Msds)

    1.3 SAFETY DATA SHEETS (MSDS) U.S. Battery has safety data sheets available for all product lines: Flooded Deep-Cycle Lead Acid Safety Data Sheet AGM Deep-Cycle Lead Acid Safety Data Sheet User Manual...

  • Page 6: Installation

    INSTALLATION The following sections contain all necessary information for properly installing your U.S. Batteries: 2.1 CABLE SIZE AND BOLT NUT SPECIFICATION Lead terminals require retightening every 30 – 60 days. Terminal Types U.S. Battery offers a variety of terminal options for Flooded lead-acid batteries with various benefits for your specific application.
  • Page 7 No Hardware Supplied - Application Uses SAE Clamp for Positive & Negative Tapered Post Note: The use of flanged nuts and other types of nuts with captive washers or other hardware not listed above is not recommended by US Battery and their use may void the battery warranty. User Manual...
  • Page 8 INSTALLATION Warning! Never put the lock washer between the cable and the terminal. The cable end must be directly in contact with the terminal. Failure to do so may result in a melted terminal and voiding of your warranty. DIAGRAM 1 Connecting Cables to Terminals Bolt Washer...
  • Page 9 QUICK TIP INSULATED TOOLS: THE USE OF LARGE CRESCENT WRENCHES OR OTHER LARGE WRENCHES >6 INCHES LONG CAN RESULT IN OVER-TIGHTENING OF TERMINALS CAUSING TERMINAL DAMAGE. SMALL 6 INCH WRENCHES ARE RECOMMENDED TO PREVENT TERMINAL DAMAGE. WRENCHES CAN BE TAPED WITH INSULATING TAPE OR DIPPED IN INSULATING MATERIAL.

  • Page 10: Speedcaps™ And Vent Caps

    INSTALLATION 2.2 SPEEDCAPS™ AND VENT CAPS SpeedCaps must remain securely installed at all times unless topping off cells with distilled water or checking the specific gravity of the electrolyte. At no point should the caps be left on the battery in the open position. Always securely close the caps. Follow the infographics below to ensure that your SpeedCaps and/or vent caps are securely installed.

  • Page 11: Terminal Cleaning And Protection

    DIAGRAM 3 Installing U.S. Battery Mfg. Co. Bayonet Caps BAYONET CAP INSTALLATION STEPS 1. Line up the Bayonet caps with the vent 4. If all steps were followed correctly, your wells. battery will look like step 5. 2. Make sure the caps sit flat within the 5.

  • Page 12: Battery Orientation

    INSTALLATION 2.4 BATTERY ORIENTATION Flooded lead acid batteries must be oriented upright at all times due to the liquid elec- trolyte. Tipping of the battery more than 15 degrees may result in electrolyte spilling from the vent caps. Battery spills are not covered by warranty. AGM batteries can be oriented in any direction except upside down.

  • Page 13: Battery Environment

    The recommended temperature range for charging both FLA and AGM US Battery deep cycle batteries is 0’F to 120’F (-18’C to 49’C). The recommended temperature range for discharging both FLA and AGM US Battery deep cycle batteries is -20’F to 120’F (-29’C to 49’C). Batteries discharged at temperatures below 32’F should be recharged immediately to avoid freezing.

  • Page 14: Care And Maintenance

    CARE AND MAINTENANCE The following information will help prevent the majority of issues that are known to cause premature failure. Follow these instructions frequently to get the most out of your investment! For a quick list of important topics visit our care and maintenance webpage.
  • Page 15 DIAGRAM 4 Correct Fill Level Bottom of Fill Well Head Space Plate Tops ● After adding water, firmly install vent caps back on batteries.(See section 2.2 SpeedCaps™ and vent caps) ● Tap water may be used if the levels of impurities are within acceptable limits.

  • Page 16: Cleaning

    CARE AND MAINTENANCE 3.3 CLEANING Observe the battery for cleanliness at regular intervals and keep terminals and connec- tors free of corrosion by using a wire brush as necessary. Terminal corrosion may ad- versely affect the performance of the battery, and could be a safety hazard. ●...

  • Page 17: Charging And Equalizing

    Most chargers are automatic and pre-programmed. Some chargers allow the user to set the voltage and current values. Refer to Table 4: for charging guidelines and to US Battery’s recommended deep-cycle flooded/wet charging guidelines (Section 4.2.1). Refer to the deep-cycle AGM charging guidelines (Section 4.2.2)
  • Page 18 CHARGING AND EQUALIZING hours) to offset the thermodynamic inefficiencies inherent in the charging process. This additional capacity can be measured as a charge factor calculated by: charge Ah in / discharge Ah out. The charge factor varies with temperature, condition and age of the battery but is usually in the range of 105 - 150%.
  • Page 19 • FLOODED LEAD ACID CHARGING RECOMMENDATIONS Three-Stage Charger (Constant Current-Constant Voltage-Constant Current)* Following is the charging recommendation and charging profile using 3 stage chargers for US Battery deep cycle products. *Equalization and float charge modes are not considered to be one of the stages in a charging profile.
  • Page 20 EQUALIZING Two-Stage Charger (Constant Current-Constant Voltage)* Following is the charging recommendation and charging profile using 2 stage chargers for US Battery deep cycle products. *Equalization and float charge modes are not considered to be one of the stages in a charging profile.
  • Page 21 TABLE 4: Example of voltage settings for deep-cycle flooded lead acid batteries using a 2-stage charger 2-Stage Charger Settings for Deep-Cycle Flooded/Wet Batteries System Voltage* 6 Volt 8 Volt 12 Volt 24 Volt 36 Volt 48 Volt Bulk Charge Voltage 7.05 - 7.5 9.4 - 10 14.1 - 15 28.2 - 30...
  • Page 22 CHARGING AND EQUALIZING DIAGRAM 7 AGM 3-STAGE CHARGING WITH PULSE FINISH 3-STAGE AGM CHARGE CURVE WITH PULSE FINISH Charge Charge 3.100 Current Voltage 3.000 2.900 Stage 1 Stage 2 Finish Phase 2.800 2.700 2.600 2.500 2.400 2.300 2.200 2.100 2.000 1.900 Two-Stage Charger (Constant Current-Constant Voltage)* Following is the chargeing recommendations and charging profile using 2 stage* chargers for US...
  • Page 23 DIAGRAM 8 US Battery Recommended Charge Profile AGM 2-STAGE CHARGING 2-Stage (Constant Current - Constant Voltage) Charge Current Equalization Charge Current Charge Voltage Equalization Charge Voltage Bulk Absorption Equalization Charge Charge Charge (Constant Current (Constant Voltage 10% of C/20Ah) @2.45+/-0.05 vpc) w/ Max.

  • Page 24: Equalization Charging Recommendations

    Equalization charging also assures that all the cells are gassing enough to fully mix the electrolyte to prevent electrolyte stratification. US Battery recommends an equalization charge of 2-4 hours every 30 days or 30 cycles or whenever a specific gravity difference of over 15 points is noted among all the cells of the battery.

  • Page 25: Renewable Energy Line

    To offset these effects, US Battery has designed Renewable Energy batteries with specific design fea- tures to address failure modes such as mossing and sulfation. US Battery uses ‘moss shields’ to prevent moss shorts that can form when positive active material dislodges from the positive plates and collects under the plate connectors.

  • Page 26: Delta-Q Charging Algorithms

    4.7 DELTA-Q CHARGING ALGORITHMS The following link will take you to a US Battery Technical Service Bulletin regarding the appropriate Delta-Q charging algorithms for each battery: Delta-Q Charging Algorithms...

  • Page 27: Storage

    STORAGE The following tips will help ensure that your batteries remain in good condition during storage: ● Fully charge batteries before placing in storage. ● Store in a cool, dry location, protected from the elements. ● Disconnect from equipment to eliminate potential parasitic loads that may dis- charge the battery.

  • Page 28: Storage In Hot Environments (Greater Than 90ºf Or 32ºc)

    STORAGE DIAGRAM 10 U.S. BATTERY AGM BATTERY SELF-DISCHARGE Self-Discharge Rate RATE AT 32ºF TO 104ºF at 32ºF to 104ºF No supplementary charge required (Carry out supplementary charge before use if 100% capacity is 32ºF (0ºC) required) Supplementary charge required before use to recover full capacity.
  • Page 29 DIAGRAM 11 Electrolyte Freezing Point vs State of Electrolyte Freezing Point vs Charge of FLA Batteries State of Charge of FLA Batteries Specific Gravity 1.000 1.040 1.080 1.120 1.160 1.200 1.240 1.280 -100 100% State of Charge DIAGRAM 12 Electrolyte Freezing Point vs State of Electrolyte Freezing Point vs Charge of AGM Batteries State of Charge of AGM Batteries...

  • Page 30: Performance Optimization

    ● Read and understand the information provided here regarding proper installa- tion, care and maintenance, and storage. ● US Battery recommends that you limit the depth of discharge to 50% of the 20hr capacity in order to optimize cycle life vs runtime.

  • Page 31: Cycle Life

    6.2 CYCLE LIFE The number of cycles a US Battery will deliver depends highly upon its depth of dis- DIAGRAM 13 charge (DOD). In other words, if you discharge Expected Life Cycles vs. DOD (XC, XC2, & AGM) the battery at a lesser...

  • Page 32: Discharge Voltage Cutoff

    PERFORMANCE OPTIMIZATION 6.3 DISCHARGE VOLTAGE CUTOFF A convenient method for optimizing runtime vs DOD is to adjust the discharge cutoff voltage. Diagram 15 shows the discharge cutoff voltage vs discharge rate to achieve ~80% DOD at that rate. To limit the DOD to less than 80% DOD, use a cutoff voltage that is higher than the values shown.
  • Page 33 the problem can also result from a poorly performing charging system. Keep in mind that battery chargers are subjected to temperature extremes and corrosive environ- ments that can affect their performance over time. So before you replace another set of batteries, try these diagnostic procedures to ensure your charger and charging meth- ods are working properly: 1.
  • Page 34 Armed with this information, you may be able to determine that the charger is not work- ing properly if: a) Either the on-charge voltage for the battery pack or on-charge voltage for each battery fail to reach the equivalent of 2.5 volts per cell times the number of cells connected in series.

  • Page 35: What To Expect From

    ● US Battery’s batteries take 30 to 80 cycles to cycle up to peak capacity. ● When operating batteries at temperatures below 80°F (27°C)

  • Page 36: Troubleshooting

    TROUBLESHOOTING The following troubleshooting tips are for general diagnosis of battery issues only. There may be issues that occur within the batteries that aren’t addressed in this sec- tion. For help with this section and interpreting the results, contact our technical sup- port group by filling out the support form.

  • Page 37: Discharge Testing

    8.3 DISCHARGE TESTING ● Ensure that all charging sources and loads are disconnected from the battery. ● Connect and start the discharger at the desired discharge rate. ● Record the runtime when the discharger is finished. ● The runtime has to be corrected for temperature since the ratings that will be used for comparison were determined at 80ºF.

  • Page 38: Open Circuit Voltage Testing

    TROUBLESHOOTING ● If the end-of-charge voltage does not exceed the values above, check the char- ger to ensure the proper output is being maintained. Recharge the batteries and measure again. If the pack voltage is still low, you may have a bad battery. ●...
  • Page 39 TABLE 8 Flooded Lead Acid Battery State of charge vs Specific Gravity and Open Circuit Voltage Specific Open-Circuit Voltage Gravity Depth of State of Corrected Discharge Charge to 80ºF 48V 108V 100% 1.270 6.37 8.49 12.73 25.46 38.20 50.93 114.7 1.246 6.31 8.41...

  • Page 40: Additional Information

    ADDITIONAL INFORMATION 9.1 PRODUCT SPECIFICATION SHEETS TABLE 10 Flooded Deep-Cycle Lead Acid Batteries 6 VOLT BATTERIES 8 VOLT BATTERIES 12 VOLT BATTERIES US1800 XC2 US8VGCE XC2 US12VE XC2 US2000 XC2 US8VGC XC2 US12V XC2 US2200 XC2 US8VGCHC XC2 US12VRX XC2 US125 XC2 US8VHATB XC2 US12VXZ XC2...

  • Page 41: Short Circuit Current

    ● You now have the appropriate breaker size needed for your system. 9.3 DATE CODES Date codes are found on all US Battery products indicating the month, year, and facto- ry that they were manufactured. ● Flooded Lead Acid: For flooded lead acid batteries, the date code is stamped on the positive terminal using two letters and a number.

  • Page 42: C-Rates

    ADDITIONAL INFORMATION ● AGM: The AGM batteries have a date that is laser etched into the cover of the bat- tery. The date is written DIAGRAM 18 either in the format DDMMYY or YYM- MDD. If the date code were to be 150914 or 140915, the battery would be manufactured on September 15th,...

  • Page 43: Warranty

    BWT: Battery Watering Technologies ● Flow-Rite Controls 9.7 PRODUCT COMPARE US Battery manufactures 6V, 8V, & 12V deep-cycle lead acid batteries in a variety of capacities and sizes: Product Compare 9.8 BATTERY DEALERS NEAR YOU US Battery authorized distributors and dealers are found throughout the United States and around the world.

  • Page 44: Frequent Scenarios

    U.S. Battery does not recommended that a system exceed 3 strings of batteries connected in parallel. • Charge voltage may be too low. Verify they meet US Battery recommended charging parameters for Flooded batteries. • An increase in Absorption charge time may be necessary. Increase in 15 to 30 minute increments as necessary.
  • Page 45 BATTERY CASES ARE BULGING ON THE SIDES. • As batteries age, some bulging of the side and end walls caused by growth of internal components is normal. • Due to the weight of electrolyte, some case bulging is normal with new batteries. •...

  • Page 46: Battery Recycling

    BATTERY RECYCLING MY BATTERIES ARE BOILING. • This is called gassing and is a normal process when properly charging your batteries. As lead acid batteries recharge, the voltage increases to the point that electrolysis begins. Electrolysis is the separation of water molecules into its constituent parts, hydrogen and oxygen.

  • Page 47: Terminology

    Watt-Hr per kilogram – Gravimetric Energy Density, a measure of a battery’s energy per unit weight Watt-Hr per liter – Volumetric Energy Density, a measure of a battery’s energy per unit volume XC2 – Xtreme Capacity 2, US Battery’s proprietary paste formula User Manual...

  • Page 48: Notes

    NOTES __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________...
  • Page 49 _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ User Manual...
  • Page 50 NOTES __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________...
  • Page 51 _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ User Manual...
  • Page 52 Data references within this publication are nominal and should not be considered or construed as maximum or minimum values for specifications or for final design. Data for these product types and models may vary from what is shown in this publication, and U.S.

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