TROJAN T-105 PLUS 6V 225Ah Deep Cycle Flooded Battery User Manual

1. Introduction

This manual provides essential information for the safe and effective use of your TROJAN T-105 PLUS 6V 225Ah Deep Cycle Flooded Batteries. Please read these instructions thoroughly before installation, operation, or maintenance to ensure optimal performance and longevity of your batteries. This product typically includes six (6) TROJAN T-105 PLUS batteries, designed for deep cycle applications.

2. Safety Information

Deep cycle flooded batteries contain corrosive sulfuric acid and produce explosive hydrogen gas. Improper handling can lead to severe injury or property damage. Always adhere to the following safety precautions:

• Personal Protective Equipment (PPE): Always wear safety glasses, acid-resistant gloves, and protective clothing when handling batteries.
• Ventilation: Ensure adequate ventilation during charging and operation to disperse hydrogen gas. Avoid enclosed spaces.
• Ignition Sources: Keep sparks, flames, and smoking materials away from batteries. Hydrogen gas is highly flammable.
• Acid Contact: If acid contacts skin or eyes, flush immediately with water for at least 15 minutes and seek medical attention. Neutralize spills with baking soda.
• Lifting: These batteries are heavy. Use proper lifting techniques or equipment to prevent injury.
• Tools: Use insulated tools to prevent short circuits. Remove jewelry before working with batteries.
• Shipping and Handling: Inspect packaging for damage upon delivery. Verify the quantity and condition of batteries before signing for shipment.

3. Product Overview

The TROJAN T-105 PLUS is a 6-volt, 225 amp-hour (Ah) deep cycle flooded lead-acid battery, engineered for robust performance in demanding applications such as golf carts, renewable energy systems, floor machines, and aerial work platforms. Its deep cycle design allows for repeated discharge and recharge cycles, providing reliable power over an extended lifespan.

4. Setup and Installation

Proper installation is critical for safety and performance. Follow these steps carefully:

1. Inspection: Before installation, visually inspect each battery for any signs of damage, cracks, or leaks. Ensure terminals are clean and free of corrosion.
2. Ventilation: Install batteries in a well-ventilated area, away from heat sources and direct sunlight.
3. Orientation: Always install batteries in an upright position.
4. Connections: Connect batteries in series or parallel according to your system's voltage and capacity requirements. For a 36V system using six 6V batteries, connect them in series. For a 48V system using eight 6V batteries, connect them in series. Ensure all connections are tight and secure.
5. Terminal Torque: Apply the specified torque to terminal connections to prevent loose connections, which can cause overheating and damage.

Wiring Diagram Example (for 36V system with 6 batteries):

• Connect the positive terminal of Battery 1 to the negative terminal of Battery 2.
• Connect the positive terminal of Battery 2 to the negative terminal of Battery 3.
• Continue this pattern until the positive terminal of Battery 5 is connected to the negative terminal of Battery 6.
• The remaining negative terminal of Battery 1 and positive terminal of Battery 6 will be your main system terminals.

5. Operating Instructions

Once installed, your TROJAN T-105 PLUS batteries are ready for operation. Adhere to these guidelines for optimal performance:

• Initial Charge: Fully charge new batteries before their first use. This conditions the battery for optimal performance.
• Charging: Use a charger specifically designed for flooded lead-acid deep cycle batteries. Follow the charger manufacturer's instructions. Avoid overcharging or undercharging.
• Discharge: Avoid discharging batteries below 50% Depth of Discharge (DoD) for maximum cycle life. Occasional deeper discharges are acceptable but will reduce overall battery life.
• Temperature: Battery performance is affected by temperature. Operate batteries within recommended temperature ranges (typically 77°F / 25°C). Extreme temperatures can reduce capacity and lifespan.

6. Maintenance

Regular maintenance is crucial for extending the life and performance of your flooded deep cycle batteries:

• Watering: Check electrolyte levels regularly (monthly or more frequently in hot climates or with heavy use). Add distilled water to cover the plates, but do not overfill. Never add acid.
• Cleaning: Keep battery tops and terminals clean and dry. Use a solution of baking soda and water to neutralize any acid residue, then rinse with clean water and dry thoroughly.
• Terminal Inspection: Periodically inspect terminals for corrosion and tightness. Clean corroded terminals with a wire brush and apply a thin layer of anti-corrosion grease.
• Voltage Checks: Monitor individual battery voltages to ensure they are balanced. Significant voltage differences may indicate an issue.
• Specific Gravity: Use a hydrometer to check the specific gravity of the electrolyte in each cell. This indicates the state of charge and health of the battery.

7. Troubleshooting

If you encounter issues with your TROJAN T-105 PLUS batteries, consider the following common problems and solutions:

8. Specifications

9. Warranty and Support

For warranty information and technical support, please contact TROJAN Battery Company directly or an authorized TROJAN dealer. It is important to purchase batteries from authorized distributors to ensure warranty validity. Keep your proof of purchase for any warranty claims.

For further assistance, visit the official TROJAN website or consult your local authorized dealer.