INSTALLATION AND OPERATION MANUAL - Fullriver Battery · • Do not place any objects on top of a battery. • Do not smoke near a battery. • Keep flames, sparks and metal objects

INSTALLATION ANDOPERATION MANUAL

fullriverbattery.com

FULLRIVER BATTERY3823 Mission oaks Blvd, ste a

CaMarillo, Ca 93012

toll Free: (800) 522-8191 int’l: (805) 484-7900

www.FullriverBattery.CoM

This publication is protected by copyright. All rights are reserved. At no point, may any part of this publication be copied, reproduced, or transmitted by any means or any format without prior written consent from Fullriver Battery.

Fullriver Battery is not liable for direct, indirect, special, exemplary, incidental or consequential damages that may result from any information provided in or omitted from this manual, under any circumstances.

Fullriver Battery reserves the right to make adjustments to this manual at any time, without prior notice or obligation.

Fullriver Battery and the Fullriver Battery logo are registered trademarks of Fullriver Battery Mfg. Co. Ltd.

CONGRATULATIONS ON YOUR PURCHASE OF A FULLRIVER BATTERY!

Maximize the performance of your new batteryby thoroughly reading this manual.

Table of Contents

1. GETTING STARTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1.1 - Safety 1.2 - Equipment checklist

2. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 2.1 - Selecting the appropriate cable size 2.2 - Terminal connections 2.3 - Battery orientation 2.4 - Series connections 2.5 - Parallel connections 2.6 - Series / parallel connections 2.7 - Cross tying batteries in parallel packs 2.8 - Charging batteries before use

3. OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 3.1-Temperatureeffectsonbatteryperformanceandlife 3.2 - Operating temperature range 3.3-Lowdischargerateeffects 3.4 - Depth of Discharge (D.O.D.) vs. Battery Life

4. CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11 4.1 - Charger inspection 4.2 - Charging your Fullriver batteries 4.3 - Charging temperature range 4.4 - Charging parameters 4.4.1 - Current 4.4.2 - Voltage settings 4.4.3 - Temperature compensation

5. STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13 5.1-Batterystorageprocedure 5.2-Temperatureeffectsonself-discharge 5.3 - Storage temperature range

6. TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-16 6.1 - Test preparation 6.2 - Open circuit voltage test 6.3 - Discharge test 6.4 - Optional test 6.5 - CCA test 6.6 - Battery replacement instructions

7. YOUR CLEAN-GREEN ENERGY SOLUTION . . . . . . . . . . . . . . . . . . . . . . 16-17 7.1-Fullriverproducts 7.2 - Fullriver manufacturing 7.3-Solarsettingrecommendations

8. TRANSPORTATION INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

A. APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 A.1 - Temperature ranges A.2 - State of Charge (S.O.C.) vs. Open Circuit Voltage (O.C.V.) A.3-Bolt/NutSpecifications

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Notes


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BeforeinstallingyourFullriverbattery,pleaseadheretothefollowingsafetyguidelinesandmakesurethatyouhavetheproperequipmentforinstallation,operation,anddiagnostictesting.

1.1 - SAFETY

PROTECT YOURSELF AND PROTECT YOUR BATTERY

• Wearprotectivegear,includinggloves,whenhandlingabattery.

• Installandremoveabatteryusingtheliftinghandlesprovided.

• Useawrenchwitharubbercoatedhandleforinstalling,tightening,orremoving battery connections.

• Do not place any objects on top of a battery.

• Do not smoke near a battery.

• Keepflames,sparksandmetalobjectsawayfromabattery.

• Chargebatteriesinaventilatedarea-althoughAGMandGelbatteriestypicallydonotreleasegas.Thesafetyvalvemayopentoalleviateexcesspressureifthebatteryisover-charged.

ALWAYS USE CAUTION AROUND A BATTERY

1.2 - EQUIPMENT CHECKLIST

Gloves

Wrenchwithinsulated/rubbercoatedhandle

Voltmeter

Charger

Discharger (if available)

Getting Started


Properbatteryinstallationisthefirststepingettingthebestperformanceoutofyour Fullriver battery.

2.1 - SELECTING THE APPROPRIATE CABLE SIZE

Cablesmustbesizedtocarrythemaximumexpectedload.Under-sizedcablescanresultinover-heating,meltedconnectionsandareapotentialfirehazard.

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.

Tosignificantlyreducetheamountofheatgeneratedattheterminals,usecableswithsolder-dippedends.

Installation

25

30

40

55

75

95

130

150

170

265

360

Ampacity (Amps)14

12

10

8

6

4

2

1

1/0

2/0

3/0

Cable Gauge (AWG)

TABLE 1


2.2 - TERMINAL CONNECTIONS

Terminalconnectionsmustbetightenedusingthecorrecttorquevaluesasdefinedin TABLE 2below.Overorundertightenedconnectionscanresultinterminalbreakage,over-heatingand/ormeltdown.Usingthepropertorquevaluewillprovideoptimumconductivity.Toavoidashortcircuit,useawrenchwithaninsulatedorrubbercoatedhandlewhenmakingterminalconnections.SeeDIAGRAM 1 below for proper washer placement.

NEVER place a washer between the mating surfaces of the terminals andcables.Thiswillcompromiseelectricaltransmissionandincreaseresistance,resultinginextremeheatgenerationandprobableterminalmelting.

Loctite®Threadlockermaybeusedtobettersecuretheterminalconnections. Be careful not to get Loctite® between the mating surfaces of the terminal.

Installation

DIAGRAM 1

Terminal Type ft-lbs lbs-in Nm Terminal Type ft-lbs lbs-in Nm

M6, AP 4.1-5.8 50-70 5.6-7.9 M10M (Stud) 7.7-9.6 92-115 10.4-13

M8 7.1-7.9 85-95 9.6-10.7 3/8” Stud 8.9-12 106-150 12-16.9

M10 9.6-12 115-141 13-16 FR45 5.8-7.4 70-90 7.9-10.1

M6M (Stud) 3.3-4.6 40-56 4.5-6.3 TP06 (AP) 3.3-4.6 40-56 4.5-6.3

M8M (Stud) 4.9-6.3 58-75 6.6-8.5 TP08/TP68 (AP) 5.2-6.9 63-83 7.1-9.4

TERMINAL TORQUE SPECS


2.3 - BATTERY ORIENTATION

Theidealplacementofbatteriesisupright.AGMandGelbatteriescanbeplacedontheirsideifnecessary.Itispreferredthatallthebatterieswithinapackbeplacedinthe same orientation.

NEVERplacebatteriesinaninvertedorientation(terminalspointedtowardsground).

2.4 - SERIES CONNECTIONS

Thereismorethanoneoptiontomeetyourvoltagerequirements.Forexample,fora12voltsystem,youmayuseone(1)12voltbatteryortwo(2)6voltbatterieswiredinaseriestomakeupthe12volts.Youmayuseasmanybatteriesasyouneedtomake up the system voltage. Connect the positive of one battery to the negative ofthenextthroughtheentirestring.SeeDIAGRAM 2 below for the proper series connection.

Installation

Series Connection:Voltage is increased in a series connection

Two 6V, 224AH batteries = 12V, 224AH

DIAGRAM 2


2.5 - PARALLEL CONNECTIONS

Thereismorethanoneoptiontomeetyourenergyrequirements.Forexample,tomeet the requirements for a 210 Amp-Hour system, you may use one (1) 210 Amp-Hourbatteryortwo(2)105Amp-Hourbatterieswiredinparalleltomakeupthe210Amp-Hours.Connectallthepositiveterminalstogetherandallthenegative terminals together in the string. See DIAGRAM 3 below for proper parallel connection.

2.6 - SERIES / PARALLEL CONNECTIONS

Batteriescanbeconnectedinbothseriesandparalleltoattainthedesiredsystemvoltageandenergyrequirements.SeeDIAGRAM 4 below for proper series / parallel connections.

Foroptimumperformance,thesystemspositiveandnegativeleadsshouldbeconnecteddiagonallyopposite(catty-corner)fromeachother.

Installation

Parallel Connection:Capacity is increased in a parallel connection

Two 12V, 105AH batteries = 12V, 210AH

DIAGRAM 3

Series/Parallel Connection:Voltage and capacity are increased in aseries/parallel connection

Four 12V, 115AH batteries = 24V, 230AH

DIAGRAM 4


2.7 - CROSS TYING BATTERIES IN PARALLEL PACKS

Inordertomaintainbalanceinparallelbatterypacks,itisbesttocrosstiethe batteries.Thismethodofconnectionwillmaximizetheperformanceandlifeofyourbatterysystem.Cross-tyingbatteriesmeansconnectingpositivetopositivesandnegativestonegativesofeachadjacentbatteryintheset.SeeDIAGRAM 5 below for propercrosstyingconnections.Thedottedlinesrepresentthecrosstiedcables.

Leavesomespacebetweenbatteriesforairflowandminorbatteryexpansion.

2.8 - CHARGING BATTERIES BEFORE USE

NewAGMorGelbatteriesthathaveonlybeenstoreduptosixmonthswillnotneedtobechargedpriortobeingputintoservice.

IfnewAGMorGelbatterieshavebeenstoredformorethansixmonths,and/orinanexceptionallyhotenvironment,achargemaybenecessarypriortobeingputintoservice.Also,ifthebatteriesarenotchargedpriortobeingputintoservice,youmayexperienceaslightreductioninrangeonthefirstcycle.

Checktheopencircuitvoltage(O.C.V.)ofeachbatteryinthesetandifanybatterywithin the set is less than the values in TABLE 3 above, recharge the battery set.

Installation

< 2.0 Volts

< 6.2 Volts

< 8.3 Volts

< 12.5 Volts

< 16.7 Volts

Open Circuit Voltage (O.C.V.)2 Volt

6 Volt

8 Volt

12 Volt

16 Volt

Battery Nominal Voltage

TABLE 3

DIAGRAM 5


Theperformanceandlifeofabatterywillvarywiththeapplication,usage,temperatureanddepthofdischarge.AGMandGelbatteriestendtodeliverahighercapacitythanrated(upto10-15%higher)untiltheyarebrokenin(approximately30cycles)andsettleattheirratedcapacity.

3.1 - TEMPERATURE EFFECTS ON BATTERY PERFORMANCE AND LIFE

Operatingbatteriesabove80°F(27°C)willyieldruntimesabovetheratedcapacitywhileoperatingbatteriesbelow80°F(27°C)willyieldruntimesbelowtherated capacity.Coldtemperaturescansignificantlyreducebatterycapacity(asshowninthe chart below).

Although higher temperatures increase the battery capacity, they also accelerate corrosionandreduceoverallbatterylife.Forexample,batteriesoperating continuouslyat100°F(37.8°C),couldexperienceasmuchasa25%reductioninlife.

3.2 - OPERATING TEMPERATURE RANGE

Operation

-40°F to 160°F

(-40°C to 71°C)

Maximum5°F to 104°F

(-15°C to 40°C)

Recommended

TABLE 4


3.3 - LOW DISCHARGE RATE EFFECTS Batterycyclelifewillbereducedwhentheconstantloadappliedinacyclicapplicationisatorbelow0.7%ofthetotalAhinthebatterybank(C20rating).Thisisduetoahigherrateofsulfationoccuringinthemiddleoftheplatethatwillcauseareductioninavailablecapacitywhichinturnsincreasesthedepthofdischargeovertime.Anefforttoeitherincreasetheloadabove0.7%ofC20and/orreducethesizeofthebatterybank’scapacitysotheloadisabove0.7%ofC20shouldbeputforthifpossible. 3.4 - DEPTH OF DISCHARGE VS. BATTERY LIFE

Batterycyclelifewillvarysignificantlydependingonthedepthofdischarge.The deeperthedepthofdischarge,thefewerthecyclesabatterywilldeliver.Conversely,theshallowerthedepthofdischarge,themorecyclesabatterywilldeliver(asshownin the chart below).

Tooptimizethehealthofyourbattery,limitdischargeto80%orless.

Operation

CYCLE LIFE vs DEPTH of DISCHARGE (DOD)100%

90%

80%

70%

60%

50%

40%

30%

20%

10%

0%

DO

D

0 500LIFE CYCLES (per BCI)

1000 1500 2000 2500 3000 40003500 4500 5000 5500 6000

*(Based on BCI Testing @ 2-hr Rate)

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UsingtheproperchargeriscriticaltotheperformanceandlifeofyourAGMorGelbattery.IfyouarenotsureifyouhavetherightchargerforAGMorGelbatteries, please call our technical support line at (800) 522-8191 or email [email protected].

4.1 - CHARGER INSPECTION

1. Thechargercableshouldbeinsulatedandfreeofbreaksorcuts.

2. Thecableconnectorsshouldbecleanandproperlymatedwiththebattery terminals to ensure a snug connection.

3. Thecharger’sACcordshouldbefreeofbreaksorcutsandthewallplugshouldbeclean.

4.2 - CHARGING YOUR BATTERIES

1. UseanAGMchargerorsettingwheneveravailableforAGMbatteries.UseaGelchargerorsettingwheneveravailableforGelbatteries.

2. NeveruseaGELchargerorsettingonanAGMbattery,asitwillunderchargethebatteryandsignificantlyreducebatterycapacityandlife.

3. Many,butnotall,wetbatterychargerswillworkforanAGMbattery.Calltechnical support at (800) 522-8191 or email [email protected] toverifyyourcharger.Bepreparedtoprovidethemakeandmodelofyourcharger.

4. Batteriesshouldbefullychargedaftereachuse.Opportunitychargingcanbedone,butthebatteriesshouldbefullychargedatleasteveryotherdayiftheyareuseddaily.

5. Chargeinaventilatedarea,asgasesmaybereleasedthroughthepressurereliefvalveifthebatteriesareexcessivelyover-charged.

6. Ifthechargerdoesnothavetemperaturecompensation,avoidchargingattemperatures above 122°F (50°C).

4.3 - CHARGING TEMPERATURE RANGE

4.4 - CHARGING PARAMETERS

Mostchargerscomepre-setfromthefactory.Ifyourchargerispre-programmed,usetheinformationbelowtocheckifthesettingsarecompatiblewithAGMorGelbatteries.Ifyouhaveaprogrammablechargerorinverter,usethefollowinginformation for settings.

Charging

Yes

No

5°F to 122°F (-15°C to 50°C)

32°F to 104°F (0°C to 40°C)

Temp Compensation Recommended

TABLE 5

-40°F to 160°F (-40°C to 71°C)

5°F to 122°F (-15°C to 50°C)

Maximum


4.4.1 - CURRENT

All Models (excl. FSG): The recommendedbulkcurrentis20-25%ofthe20HrAHcapacityor0.20xC20(20Hr.capacityinAH).Themaximum allowable bulk current is 35%ofthe20Hr.AHcapacityor0.35xC20(20Hr.capacityinAH),unlessspecified.

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 recommendedbulkcurrentis12.5%ofthe10Hr.AHcapacityor0.125xC10(10Hr.capacityinAH).Themaximumallowablebulkcurrentis15%ofthe10Hr.AHcapacityor0.15xC10(10Hr.capacityinAH),unlessotherwisestated.

Example: FSG1660-2 is rated at 1110AH @ 10 Hrs. The recommended bulk current is 0.125 x 1110 = 139 Amps The maximum bulk current is 0.15 x 1110 = 167 Amps

4.4.2 - VOLTAGE SETTINGS (BOLD IS RECOMMENDED SETTING)

4.4.3 - TEMPERATURE SETTINGSIf you have a programmable charger or inverter that has a temperature compensationsetting,itshouldbesetto-4mV/°C/cellor-2mV/°F/cell.TABLE 8 below has the temperature compensation voltage values for a 12V battery. For a 24V, 36V or 48V system, multiply the values in the table by 2, 3 or 4 respectively.

Charging

TABLE 6

Bulk

Absorption

Float

Charge State14.4-14.7 V

14.4-14.7 V13.6-13.7 V

12 Volt AGM19.2-19.6 V19.2-19.6 V

18.2 V

16 Volt AGM28.8-29.4 V

28.8-29.4 V27.2-27.4 V

24 Volt AGM57.6-58.8 V

57.6-58.8 V

54.4-54.8 V

48 Volt AGM

Bulk

Absorption

Float

Charge Stage

15.30 V

15.30 V

14.25 V

32°F (0°C)

15.06 V

15.06 V

14.01 V

50°F (10°C)

14.82 V

14.82 V

13.77 V

68°F (20°C)

14.70 V

14.70 V

13.65 V

77°F (25°C)

14.58 V

14.58 V

13.53 V

86°F (30°C)

14.34 V

14.34 V

13.29 V

104°F (40°C)

TABLE 8

TABLE 7

Bulk

Absorption

Float

Charge State14.4-14.7 V

14.4-14.7 V

13.6 V

12 Volt FSG28.8-29.4 V

28.8-29.4 V

27.2 V

24 Volt FSG57.6-58.8 V

57.6-58.8 V

54.6 V

48 Volt FSG14.1-14.4 V

14.1-14.2 V

13.6 V

12 Volt DCG

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AGMandGelbatterieshaveamuchlongershelflifethanwet,lead-acidbatteries.Withaself-dischargeofonly1-3%permonth,AGMandGelbatteriescanbestoredforayearorlongerwithoutneedingtobecharged.

5.1 - BATTERY STORAGE PROCEDURE

1. Chargebatteriesbeforetheyareplacedinstorage.

2. Disconnectbatteriesfromtheequipmentandchargertoeliminateanyparasiticloads.

3. CheckthebatteriesbasedonconditionsandscheduleinTABLE 9 below.

4. Check the open circuit voltage (OCV) of each battery in the set. If any battery within the set is less than the values in TABLE 10 below, recharge the battery set.

5. Ifthechargerhasamaintenancemode,selectthatmodetoboostcharge batteries. Otherwise, run the normal charge cycle.

6. IfthebatteriesarestoredshorterthanthetimeperiodsinTABLE 9,theydonotneedtoberechargedpriortobeingputbackintoservice.

AGMandGelbatteriesdonothaveamemoryeffect;sothereisnoneedtofullydischargebatteriespriortocharging.

Storage

9 months

6 months

3 months

TimeBelow 68°F (20°C)

68°F to 86°F (20°C to 30°C)

Above 86°F (30°C)

Temperature

TABLE 9

< 2.0 Volts

< 6.2 Volts

< 8.3 Volts

< 12.5 Volts

< 16.7 Volts

Open Circuit Voltage (O.C.V.)2 Volt

6 Volt

8 Volt

12 Volt

16 Volt

Battery Nominal Voltage

TABLE 10


Storage

5.2 - TEMPERATURE EFFECTS ON SELF-STORAGE

Ifthestorageenvironmentishot,batterieswillself-dischargefasterthaninacoldenvironmentasshowninthechartbelow.TheFSGserieswilldischargeapproximately40-60%slowerabove86°Fthanthechartbelowindicates.

BatteriesCANbesafelystoredonconcretefloorswithoutanynegativeeffects.ConcretefloorsDONOTdrainbatteries.

5.3 - STORAGE TEMPERATURE RANGE

Storebatteriesinacool,dryenvironmenttominimizeselfdischarge.

-40°F to 160°F (40°C to 71°C)

Maximum5°F to 122°F (-15°C to 50°C)

Recommended

TABLE 11

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Testingbatteriescanbecomplexandtherearemanyapplicationspecificvariablesthatcannotbeconsideredinonesimpletest.Thissectionisaguidetohelpyoudeterminetheoverallconditionofyourbatteries.ContactyourlocalFullriverBatterydistributorforassistance.

6.1 - TEST PREPARATION

1. Checkthatthebatterycablesareingoodworkingcondition.Replaceanydamagedorbrokencables.

2. CheckthatallterminalconnectionsaretightenedtopropertorquespecificationasdescribedinTABLE 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. Checkandrecordopencircuitvoltage(O.C.V.)ofeachbattery.

2. If all of the batteries are below 2.0V (2V battery), 6.1V (6V battery), 8.1V (8V battery),12.2V(12Vbattery),or16.3V(16Vbattery)thesethasfailed.Replacetheentiresetofbatteries.Inthissituation,thebatterysethaseitherprovidedallofitsavailableenergyorwasseverelyabused.

3. Otherwise, any battery that is 0.15V lower than the highest battery voltage (2V battery), 0.25V lower than the highest battery voltage (6V battery), 0.35V lower than the highest battery voltage (8V battery), 0.5V lower than the highest battery voltage (12V battery), 0.7V lower than the highest battery voltage (16V battery),mighthavefailed.Makenoteofthesebatteries.

Allbatteriesinagoodsetshouldbeabove2.1V(2Vbattery),6.4V(6Vbattery),8.5V(8Vbattery),12.7V(12Vbattery),and17.0V(16Vbattery)whenfullychargedafteratleast 8 hours of rest.

6.3 - DISCHARGE TEST (if you do not have a discharger, proceed to section 6.4. if you have a Full Throttle series battery, proceed to section 6.5)

1. Connectandstartdischarger.

2. Recordminutes(runtime)whendischargeiscomplete.Correctruntimeminutes for battery temperature using the following formula: Mc = Mr [1 - 0.009 (T-27)] Where Mcisthecorrectedminutes,MristheminutesrecordedandT is the temperatureattheendofthedischargein°C.

Testing


3. Ifthesetrunsmorethan60%ofitsratedcapacity,thebatteriesaregoodandthe test is complete.

4. Ifthesetrunslessthan60%ofitsratedcapacity,reconnectthedischarger.Whileunderthedischargeload,recordtheendofthedischargevoltageforeach battery.

5. Thebatteriesthatare0.5Vlowerthanthehighestendofdischargevoltageshouldbenoted.

6. Ifthesetdeliveredlessthan60%ofitsratedcapacity,andthesamebatteriesthatwerenotedinSTEP 3 of SECTION 6.2werealsotheonesnotedinSTEP 5 of SECTION 6.3,thosebatteriesaremostlikelyfailedandshouldbereplaced.Follow the replacement instructions in SECTION 6.6 below.

7. Otherwise,pleasecontactyourlocalFullriverBatterydistributortoreviewyourdataindetail.Youcanalsoreachtechnicalsupportbycalling (800) 522-8191 or emailing help@fullriverbattery.com.Additionaltestingmayberequireddependingonyourspecificapplication.

6.4 - OPTIONAL TEST

After completing SECTION 6.1andSECTION 6.2, follow these steps:

1. Operatethevehicle/equipmentuntilbatteryperformancedecreases.

2. Recordvoltagesduringandafteroperation.

3. Recordtimeanddistanceofoperation.

4. Providethevoltage,time,anddistancedatatoaFullriverBatterydistributoror to Fullriver Battery technical support at (800) 522-8191 or email [email protected].

5. Thisdatawillbeanalyzedincomparisontowhatisexpectedofthe vehicle/equipment.

6.5 - CCA TEST (only applicable to Full Throttle series batteries)

1. ConnectandstartcarbonpileloadtesteraccordingtoCCAratinglistedonbattery.

2. Recordalldataduringtest(startvoltage,endvoltage,pass/fail,testermodel,etc.).

3. Providethevoltage,time,andtesterdatatoaFullriverBatterydistributororto Fullriver Battery technical support at (800) 522-8191 or email [email protected].

Testing

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6.6 - BATTERY REPLACEMENT INSTRUCTIONS

Aslongasitissafetodoso,chargethesetofbatteriesbeforereplacingthefailedonestomakesurethegoodbatteriesarefullycharged.

Ifpossible,replacefailedbatterieswithgoodbatteriesaroundthesameagefromanotherpieceofequipment.Trytoavoidmixingnewbatteriesinequipmentwitholdbatteries. Put all new batteries in the same piece of equipment. 7.1 - FULLRIVER PRODUCTS

FullriverBatteryproducessealed,maintenance-freebatteriesthatarenon-hazardous,non-spillable.Duringnormaloperation,ourbatterieswillnotreleaseanyharmfulgasesandwillnotleakanyacidicelectrolyteintotheenvironment.

Fullriverbatteriesareclassifiedassafeforair,sea,andgroundtransportation.Theymeet all requirements of the International Air Transport Association (I.A.T.A.), the InternationalCivilAviationOrganization(I.C.A.O.),theInternationalMaritime DangerousGoods(I.M.D.G.),andtheDepartmentofTransportation(D.O.T.).

Morethan98%oftheleadinbatteriesisrecycled-placinglead-acidbatteriesatthetopofthelistofmosthighlyrecycledconsumerproducts.Therecyclingloopofalead-acidbatterygoesonindefinitely. 7.2 - FULLRIVER MANUFACTURING

FullriverBatterymanufacturesbatteriesinaccordancewithinternational environmentalregulations.Wecontinuallyimproveourprocessinordertominimizewaste,recycleallwastethatisrecyclableanddiscardwastethatisnotrecyclableinaccordancewithlocaldisposalregulations.Westrictlyenforcetheuseofproper ventilationandprotectivegear.Thisenforcementhelpsminimizeemployeeexposuretoleadatapointwellbelowsuggestedlevels. 7.3 - SOLAR SETTING RECOMMENDATIONS FullriverBatteryhasasignificantpresenceandhistoryintheresidential,commercial,andRVsolarmarkets.Fromthishistory,weprovidethefollowingrecommendationsonchargecontrollerandinvertersettings: 7.3.1 - VOLTAGE SETTINGS Pleaseseetables6&7onPage11forbulk,absorption,andfloatvoltagerecommendations.

RebulkVoltageshouldbesetlowenoughtonotcausetwochargecyclesinoneday,typically12.0,24.0,or48.0V.RefloatVoltageshouldbesetslightlyunder100%OCVor 12.7, 25.4, or 50.8V.

Testing & Your Clean-Green Energy Solution


7.3.2 - ABSORPTION SETTINGS AbsorptiontimevariesperinstallationaccordingtototalbanksizeandtotalPVkW.Ourmaximumabsorptiontimeis4hours,howevermostinstallationsneed2-3hours on average. To estimate your rough absorption time, use the following formu-la: [(AH * DOD) / CHARGE AMPS * 0.85] IfyourchargecontrolleroffersasettingsuchasAbsorbEndAmps(Outback)orsim-ilarthatautomaticallytransferstofloatchargebasedonampsaccepted,absorptiontimeshouldbesetto4hoursandthissettingshouldbesettoapproximately1.75%of total bank capacity in Ah. 7.3.3 - CHARGE RATE & EQUALIZATION Chargeampsshouldbesetupto25%oftotalbankcapacityinAh.Theminimumrecommendedis10%,butverifythatyourabsorptiontimewillnotexceed4hours. Equalizationisnotrecommendedforanyofourproducts,pleasedisableequaliza-tionorsettotheminimumtimeandvoltageequaltoabsorb.Ifyouexperienceasignificantlossincapacity,pleasecontactourtechnicalsupportforfurthersupport. 7.3.4 - DEFAULT SETTINGS When custom settings are not available, please use the following options: 7.3.5 - INVERTER SETTINGS LowVoltageCutOfforLowBatteryCutOut(LVCO/LBCO)willvarybasedonhowlargeyourloadsareandmayrequireadjustmentifyourruntimeistooshort. Ifyouhaveachargecontrollersettingnotlistedabove,youmaycallourtechnicalsupportat(800)522-8191withyourchargecontroller’smake/modelandourstaffwill assist you further.

Your Clean-Green Energy Solution

TABLE 13

MagnumEnergy

MidniteSolar

Schneider/Xantrex

ManufacturerAGM 2

Switch 1-2: OFF/OFF, Switch 5-8: OFF/ON/ON/OFFAGM

Setting(s)

TABLE 14

25%

50%

80%

Depth of Discharge12.5 V

12.2 V11.8 V

12 Volt25.0 V

24.4 V23.6 V

24 Volt50.0 V

48.8 V

47.2 V

48 Volt

800.522.8191 (Toll Free)Page 18

Transportation Information

FullriverDC,FullForce,andFullThrottlebatteriesaresealedlead-acidbatteriesmadewithAbsorbentGlassMat(AGM)technology.Theelectrolyteisabsorbedintothefiberglassseparatormaterialratherthaninafree-flowingliquidform.

FullriverDCGandFSGbatteriesaresealedlead-acidbatteriesmadewithgelledelectrolytetechnology.Theelectrolyteissuspendedinathixotropicgelappliedtotheplatesratherthaninafree-flowingliquidform.

Fullriverbatteriesarenon-spillableelectricstoragebatteries.TheyareexemptfromtherequirementsofDOT’shazardousmaterialsregulationssincetheyadheretothe requirementsofcode49CFRSection173.159(D),whichstates:

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

• The battery and outer packaging must be plainly and durably marked “NON-SPILLABLE” or “NON-SPILLABLE BATTERY“

• The battery must be capable of withstanding the Vibration and Pressure Differential test specified in 49 CFR 173.159(d)(3)(i) and 49 CFR 173.159(d)(3)(ii); and

• At a temperature of 131°F (55°C), the battery must not contain an unabsorbed, free-flowing liquid, and must be designed so that electrolyte will not flow from a ruptured or cracked case.

Fullriverbatteriesareprotectedagainstshortcircuitsandaresecurelypackaged.Boththebatteriesandtheouterpackagingareclearlymarked“NON-SPILLABLE“.FullriverbatteriesweretestedbyathirdpartylabanddeterminedtobeincompliancewithDOTregulationsasstatedincode49CFRSection173.159(D).

SinceFullriverbatteriesmeetalltherequirements,theyareconsiderednon-hazardousandthereforedonotrequireaUNnumberoradditionalDOThazardousmaterial labeling.

This notice is to clarify to shippers and transporters that our batteries are packaged and marked in accordance to 49 CFR 173.159(D) and are determined to be in compliance with DOT HMR49 Non-Hazardous Materials, and the International Air Transportation Association (IATA), Special Provisions S.P. A67 & A48.

Therefore, Fullriver batteries are not restricted for shipment by air or any other means of transportation and are exempt from the hazardous material category.


Appendix

A.1 - TEMPERATURE RANGES

A.2 - STATE OF CHARGE (S.O.C) VS. OPEN CIRCUIT VOLTAGE (O.C.V.)

A.3 - BOLT & NUT SPECIFICATIONS

Storage

Operation

Charge with TC

Charge w/o TC

5°F to 122°F (-15°C to 50°C)

5°F to 104°F (-15°C to 40°C)

5°F to 122°F (-15°C to 50°C)

32°F to 104°F (0°C to 40°C)

Condition Recommended-40°F to 160°F (-40°C to 71°C)

-40°F to 160°F (-40°C to 71°C)

-40°F to 160°F (-40°C to 71°C)

5°F to 122°F (-15°C to 50°C)

Maximum

6V100

90

80

70

60

50

40

30

20

10

State of Charge (S.O.C.)

Open Circuit Voltage (O.C.V.)

6.42

6.36

6.30

6.24

6.17

6.10

6.03

5.96

5.88

5.81

8V8.56

8.48

8.40

8.32

8.23

8.14

8.04

7.94

7.84

7.74

12V12.83

12.72

12.60

12.47

12.34

12.20

12.06

11.91

11.76

11.61

16V

At 80°F (27°C)

2V2.14

2.12

2.10

2.08

2.06

2.03

2.01

1.99

1.96

1.94

17.11

16.96

16.80

16.63

16.45

16.27

16.08

15.88

15.68

15.48

FT100, FT185, FT230, FT230D, FT265

DC35, DC55, DC85, FT438, FT620

DC105, DC140, DC245, DC400, FT410,

FT410R, FT560, FT825, FT930

DC210, DC260

DC1150

AllOtherDCModels,AllOtherFTModels

6MMx1

6MMx1

8MMx1.25

8MMx1.25

10MMx1.5

8MMx1.25MM

Model Size x Thread Pitch12MM/9.5MM

16MM/13.5MM

16MM/13MM

25MM/19MM

16MM/12.5MM

20MM/17MM

Length / Max Insert

fullriverbattery.com

3823 Mission oaks Blvd, ste a CaMarillo, Ca 93012

800.522.8191 (toll Free) 805.484.7900 (loCal / int’l)

Documents

INSTALLATION AND OPERATION MANUAL - Fullriver Battery · • Do not place any objects on top of a battery. • Do not smoke near a battery. • Keep flames, sparks and metal objects