BATTERY USER MANUAL CAUTION ONE MEAN BATTERY Recommended charging, equalization and preventive maintenance procedures for Rolls Batteries.
RAILROAD & DIESEL STARTER MOTIVE POWER MARINE RENEWABLE ENERGY AGM
Table of Contents Manual ....................................................................................................................2 E quipment Needed ..........................................................................................2 Safe Handling Procedure ................................................................................2 Inspection .............................................................................................................2 Installation ..................
MANUAL Rolls Battery has been manufacturing deep cycle lead-acid batteries since 1935. Experience gained has helped us achieve an unmatched reputation along with specific measures to obtain the maximum performance and life from our product. This manual describes the recommended charging, equalization and preventive maintenance procedures for Rolls batteries in order to maximize battery life.
Wire Gauge Size Amperage 14 12 10 8 6 4 2 1 00 25 30 40 55 75 95 130 150 195 0000 260 Table 1 – Wire gauge sizing Parallel/Series Connections: Certain applications demand more voltage or more capacity than one battery’s output. By arranging the connection configuration, one is able to increase the output voltage, output capacity or both if needed. To increase voltage, connect the batteries in series as shown in Figure 1.
Rolls AGM Battery Charging Instructions To maximize the life of your Rolls battery, it is important that it is properly charged. Over and under-charging a Rolls battery will result in shortened service life. The best protection from improper charging is the use of a quality charger and routinely checking that the charger current and voltage settings are maintained. Please review the following Rolls Battery Charging Instructions.
AGM Bulk Stage The charger should deliver the initial current I1 until the voltage limit U0 is reached. Absorption Stage - the charger should maintain the voltage U0 until the current tapers to I1. The initial charge current is recommended to be set at I1 = 0.25 X C20 (Imax = 0.35 X C20) in order to fully charge the batteries within a reasonable amount of time.
AGM Constant Current Charger – IUI A constant current charger can also be used; however, it is important to adhere to the termination criteria mentioned below to minimize the chance of excessive over-charge. See Figure 2 for the recommended constant current charge profile. AGM Bulk Stage The charger should deliver the initial current I1 until the voltage limit U0 is reached. Absorption Stage - the charger should maintain the voltage U0 until the current tapers to I1.
AGM Refresh Charge If Rolls batteries are properly charged they should never require an equalizing charge. If they were not properly charged and there is a decrease in capacity, recharge the batteries and make sure they complete the entire charge cycle.
Activation of a Dry Battery (Lead Acid) Special order batteries can be shipped dry (acid shipped separately). To activate these batteries, start by removing the vent caps. Using approved battery grade electrolyte (1.265), fill each cell half way between the plates and the bottom of the vent well tube. (See Figure 4 on page 11.) It is important not to over fill the cells as the acid will expand upon charging. If the cells are too full, the acid will spill out of the top of the cells.
Activating Instructions/Maintenance for a Wet Battery (Lead Acid) Caution: Always wear the proper personal protective equipment (goggles, gloves, clothing) when handling batteries and electrolytes WARNING: • WET BATTERIES MUST BE FULLY CHARGED BEFORE BEING DELIVERED TO THE END USER. PLEASE REFER TO THE “INITIAL CHARGE OF WET BATTERIES” SECTION OF THIS DOCUMENT. • ADD DISTILLED WATER ONLY TO WET BATTERIES. UNLESS INSTRUCTED BY ROLLS TECHNICAL SUPPORT, NEVER ADD MORE ACID TO THE BATTERIES AT ANY TIME.
5. See Initial Charge below. Initial Charge A battery may not be fully charged when received. The first charge brings the battery to an operational state. Before this charging process, the cell electrolyte level should be checked. Please ensure the electrolyte (liquid) covers the plates. If this isn’t the case, add distilled water until all the plates are just submerged. It is important not to over fill because the level will rise during the charging process. Charge voltages are indicated in Table 2.
Caution: Do not add water or electrolyte to cells before initial charging. Adjust electrolyte levels only when cells are fully charged. Please contact us if you have any questions or concerns. Figure 4 – Electrolyte level Bulk Charge The first part of the charging process is the bulk charge.This is when the maximum amount of current flows into the battery bank until a desired voltage is reached. The recommended maximum current is 15% of the AH capacity of the battery bank based on the 6 hour rate.
Float Charge The batteries require a certain amount of voltage in order to maintain full charge when no load is applied. The power supply keeps the batteries at a constant full state of charge. In order to prolong battery life, the float settings on the power supply should be adjusted to the voltage indicated in Table 2. Equalization Individual cells will vary slightly in specific gravity after a charging cycle.
4. Once every hour, measure and record the specific gravity and temperature of a test cell. If the temperature rises above 46ºC and approaches 52ºC, remove the batteries from charge. 5. If severely sulfated, it may take many hours for the specific gravity to rise. 6. Once the specific gravity begins to rise, the bank voltage will most likely drop, or the charging current will increase. The charging current may need to be lowered if temperature approaches 46ºC.
Figure 5 – Temperature Probe Cleaning Batteries should be kept clean at all times. If stored in a dirty area, regular cleaning should be performed. Before doing so, assure that all the vent caps are tightly fastened. Using a solution of water and baking soda (100g per litre), gently wipe the battery and terminals with a damp sponge, then rinse with water.
Disposal Procedure Batteries must NEVER be disposed in household waste. To reduce environmental impacts, bring your battery to a certified recycling depot at the end of its life. Note: Lead-acid batteries are 97-98% recyclable. Rolls Batteries have >66% recycled lead.
BEFORE signing the delivery slip. The Company is not responsible for damaged product reported after shipment has been signed “Received in Good Condition”. NOTE: ALL SHIPMENTS SHOULD BE THOROUGHLY INSPECTED FOR DAMAGE BEFORE SIGNING THE DELIVERY SLIP.
Lead Acid Battery Glossary Absorbed (or Absorptive) Glass Mat A technique for sealed lead-acid batteries. The electrolyte is absorbed in a matrix of glass fibers, which holds the electrolyte next to the plate and immobilizes it, preventing spills. AGM batteries tend to have good power characteristics, low internal resistance, and good behavior during charging. Amp, Ampere Unit of electrical current. Abbreviated “A”. Amp-hour Unit of electrical energy, one amp of current flowing for one hour. Abbreviated Ah.
Specific Gravity The density of a material, expressed as the ratio of the mass of a given volume of the material and the mass of the same volume of water; a specific gravity greater than 1 means heavier than water, less than 1 means lighter than water. The specific gravity of the electrolyte in a battery can be used to measure the state of charge of the battery.
Rolls Battery Warranty Claim To receive a returned goods authorization for a Rolls battery that has failed, we require an analysis of the battery in question. To do so, please contact our technical support department (Tel: +44 (0)1489 570770) and a warranty claim form similar to the one shown* will be supplied for the batteries in question. Once it has been established that it is a valid warranty claim, we will process your RGA for either a replacement or credit your account.
Rolls Battery Warranty Procedure Please refer to product warranty for the specific model as terms and conditions may vary. For warranty requests and inquiries, please consult your Rolls Battery Distributor or Dealer (point of purchase). DAMAGED BATTERY YES Damaged batteries DO NOT qualify for Rolls Battery product warranty NO Check individual cell voltages < 2.1 VPC Charge battery at 0.1/c20 for 10 hours Cells < 1.250 Charge battery at 0.1/c20 for 10 hours > 2.
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Contacts Rolls Battery Europe 5 Little Park Farm Segensworth West Fareham Hampshire England UK PO15 5SJ T: +44 (0)1489 570770 F: +44 (0)1489 579913 www.rolls-battery.
