Odyssey PC310 User manual

USER’S GUIDE

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Why use ODYSSEY batteries? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
ODYSSEY SLI battery specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Pulse discharge capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
ODYSSEY storage and deep discharge recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
(A) How do I know the state of charge (SOC) of the battery? . . . . . . . . . . . . . . . . . .6
(B) How long can the battery be stored? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Charging ODYSSEY batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
(A) Selecting the right charger for your battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Concluding remarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Warranty: Full 2 – year, 3 – year, and 4 – year replacement . . . . . . . . . . . . . . . . . . . . . .8
INTRODUCTION
The ODYSSEY battery combines in one box the characteristics of two separate
batteries. It can deep cycle as well as provide enormous cranking power - it is almost
as if a champion long distance runner and a world class sprinter are one and the
same person.
These batteries are capable of providing engine cranking pulses in excess of 2250A for
5 seconds as well as 400 charge/discharge cycles to 80% depth of discharge (DOD).
A typical starting, lighting and ignition (SLI) battery can do one or the other, but not
both. It is either a sprinter or a long distance runner; ODYSSEY batteries will do both -
provide short duration high amperage pulse or low rate long duration drains.
WHY USE ODYSSEY BATTERIES?
GUARANTEED LONGER SERVICE LIFE
With an eight to twelve year design life (float) and a three to ten year service life,
ODYSSEY saves you time and money because you do not have to replace the battery
as often. ODYSSEY is warranted against factory defects for two full years in
Powersports or three full years in automotive, commercial and heavy-duty marine
applications.
SUPERIOR CRANKING AND FAST CHARGE CAPABILITY
The 5 second cranking power of ODYSSEY batteries is double to triple that of equally
sized conventional batteries, even when the temperature is as low as - 40°C (-40°F).
Also, with simple constant voltage charging (alternator or independent charger), there
is no limitation on the inrush current, so the user is assured of fast charge recovery.
MOUNTING FLEXIBILITY
The ODYSSEY battery may be installed on its sides at any angle without sacrificing
any performance attributes. There is no fear of any acid spillage as ODYSSEY recycles
the internal gas during operation or charging. The sealed design of the ODYSSEY
battery eliminates the need for an acid vent tube; eliminating the fear of acid burns or
damage to expensive chrome or paint.
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SUPERIOR VIBRATION RESISTANCE
ODYSSEY batteries are of military grade and have endured rigorous tests that
demonstrate their overall ruggedness and exceptional tolerance of mechanical abuse.
READY OUT OF THE BOX
ODYSSEY batteries are shipped fully charged. If ODYSSEY’S voltage is 12.65V or
greater simply install the battery in your vehicle and you are ready to go! If below
12.65V, boost charge following the instructions in the ODYSSEY Owner’s Manual
and/or Technical Manual.
WORRY-FREE SHIPPING
Owing to the drycell design, the US Department of Transportation (USDOT) has
classified the ODYSSEY battery as a nonspillable, so it may be shipped worry-free by
UPS/Federal Express or by air.
LONGER STORAGE LIFE
Unlike conventional batteries that need to be recharged every six to twelve weeks the
ODYSSEY battery, when fully charged, can be stored for up to 2 years at 25°C (77°F).
Simply recharge and ODYSSEY is returned to full power. At lower temperatures,
storage times will be even longer.
DEEP DISCHARGE RECOVERY
Should ODYSSEY become deeply discharged, simply recharge following instructions
in the ODYSSEY Owners Manual.
INSTALLATION
Publication No: US-ODY-UG-001 - February 2005www.odysseyfactory.com 3
PC625 installation PC2150 installation
Except PC625, PC2150 & PC2250 PC2250 installation
Bolt
Washer
Battery
3/8-16 UNC Thread
25.4mm
Max
0.74”
NTS
Bolt
Washer
Battery
Battery/Cable
Connector
18.0mm
Max
DIN
Terminal
3/8”-16
UNC Thread
Terminal
Nut

PC625 installation
1. Using procedures recommended by the manufacturer, carefully disconnect the
cables from your old battery and remove it from the vehicle. Return the spent
battery to the dealer for recycling.
2. Inspect existing battery cables for corrosion, acid damage or insulation
deterioration. Replace if any deterioration is present.
3. Position the PC625 in the battery holder and fasten firmly to the vehicle.
4. Connect the positive (+) cable from your ignition to the positive (+) battery terminal
between the two nuts, with the washer on top.
DO NOT TRY TO LOOSEN THE LOWER NUT.
5. Connect the negative (-) cable from your engine or chassis to the negative (-)
battery terminal between the two nuts, with the washer on top.
DO NOT TRY TO LOOSEN THE LOWER NUT.
6. Torque the top nuts to a maximum per specifications noted in table.
All ODYSSEY installation (except PC625, PC2150 & PC2250)
1. Using procedures recommended by the manufacturer, carefully disconnect the
cables from your old battery and remove it from the vehicle. Return the spent
battery to the dealer for recycling.
2. Inspect existing battery cables for corrosion, acid damage or insulation
deterioration. Replace if any deterioration is present.
3. Position the ODYSSEY in the battery holder and fasten firmly to the vehicle.
4. Connect the positive (+) cable from your ignition to the positive (+) battery terminal.
5. Connect the negative (-) cable from your engine or chassis to the negative (-)
battery terminal.
6. Torque the bolt/screw to a maximum per specifications noted in the table. If you
are using the accessory bolt ©, hold the brass post (A) with a vise grip and counter
torque. Do the same with the GM cable installation.
PC2150 & PC2250 installation
1. Using proper procedures as recommended by the vehicle manufacturer, carefully
disconnect the cables from your old battery and remove it from the vehicle.
Return the spent battery to the dealer for proper recycling.
2. Inspect existing battery cables for corrosion, acid damage or insulation
deterioration. Replace if any deterioration is present.
3. Position your ODYSSEY in the battery holder and fasten firmly to the vehicle.
4. Connect the positive (+) cable to the positive (+) battery terminal.
5. Connect the negative (-) cable to the negative (-) battery terminal.
6. Torque the top bolt/screw or nuts per specifications noted in table.
NOTE: All ODYSSEY batteries are valve regulated sealed batteries and never need to have water or
electrolyte (acid) added. WARRANTY WILL BE VOID IF THE BATTERY IS OPENED.
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Publication No: US-ODY-UG-001 - February 2005www.odysseyfactory.com 5
ODYSSEY SLI BATTERY SPECIFICATIONS
PC310 12 310 100 200 155 8.5 7.8 95.43 3.39 3.98 10 M4 8.9 27.1 455A
(138.0) (86.0) (101.0) (2.7) Bolt (1.0)
PC535 12 535 200 300 265 14.8 13 21 6.70 3.90 6.125 12.0 M6 40 81000A
(170.2) (99.1) (155.6) (5.4) Bolt (4.5)
PC545 12 545 185 300 240 14 12 18 7.00 3.37 5.17 12.6 M6 50 10 1200A
(177.8) (85.6) (131.3) (5.7) Bolt†(5.6)
PC625 12 625 265 440 350 18 17 27 6.70 3.90 6.89 13.2 M6 40 71800A
(170.2) (99.1) (175.0) (6.0) Stud (4.5)
M6 Bolt†
PC680 12 680 220 370 300 17 16 24 7.27 3.11 6.67 15.4 or SAE 50 71800A
(184.7) (79.0) (169.4) (7.0) 3/8” (5.6)
Receptacle
M6 Bolt†
PC925 12 925 380 625 500 28 27 52 6.64 7.05 5.04 26.0 or SAE 60 52400A
(168.6) (179.0) (128.0) (11.8) 3/8” (6.8)
Receptacle
M6 Bolt†
PC1200 12 1200 550 860 725 44 40 78 7.87 6.66 6.80 38.2 or SAE 60 4.5 2600A
(199.9) (169.1) (172.7) (17.4) 3/8” (6.8)
Receptacle
M6 Bolt†
PC1700 12 1700 875 1325 1175 68 65 142 13.02 6.62 6.93 60.9 or SAE 60 3.5 3500A
(330.7) (168.2) (176.0) (27.6) 3/8” (6.8)
Receptacle
PC2150 12 2150 1090 1545 1370 100 95 200 13.00 6.80 9.40 75.0 3/8” 150-200 2.2 5000A
(330.2) (172.7) (238.8) (34.1) Stud/ (16.9-22.6)
SAE
Dual SAE
PC2250 12 2250 1225 1730 1550 126 114 240 11.26 10.59 8.19 86.0 Dual 100 2.1 5000A
(286.0) (269.0) (208.0) (39.0) DIN (11.0)
Terminal
Nominal Capacity Reserve Length Width Height Weight Torque Internal Short
MODEL Voltage PHCA** CCA* HCA MCA (20 Hr (10 Hr Capacity inches inches inches Ibs Terminal Specs Resistance Circuit
(5 Sec) Rate - Ah) Rate - Ah) Minutes (mm) (mm) (mm) (kg) in-Ibs (mΩ)Current
(Nm max)
* Cold Start Performance S.A.E J537 JUNE 82 **Pulse Current † Can be fitted with brass automotive terminal All batteries available with metal jackets, except PC310, PC535, PC625 and PC2250 Operating temperature range: -40°C (-40°F) to 45°C (113°F) • -30°C (-22°F) to 40°C (104°F) for PC2250 • -40°C (-40°F) to 80°C (176°F) with metal jackets on all other sizes
For 3/8
Stud only

(A) How do I know the state of charge
(SOC) of the battery?
Figure 2: ODYSSEY OCV vs. state of
charge
As long as the battery has not been
charged or discharged for 6 or more
hours, Figure 2 can be used to
determine the SOC of the ODYSSEY
battery. Use a high quality digital
voltmeter to measure its open circuit
voltage (OCV). The graph shows that a
healthy, fully charged ODYSSEY battery
will have an OCV of 12.84V or higher at
25ºC.
(B) How long can the battery be stored?
Refer to Figure 3 below. At 25°C (77ºF),
these batteries can be stored for up to
2 years. The lower the temperature, the
longer the storage time. The battery
must be charged before storage.
Roughly every 10°C (18°F) increase in
temperature cuts storage time in half.
If the temperature rises to 35°C (95°F)
the battery may be stored for only
1 year before a recharge becomes
necessary. Figure 3 will apply only if the
battery is charged before storage.
Figure 3: ODYSSEY storage time at
temperatures
State of Charge (SOC), %
Open circuit voltage (OCV), V
13.0
12.8
12.6
12.4
12.2
12.0
11.8
11.6
10 20 30 40 50 60 70 80 90 100
12.84V or higher indicates
100% SOC
Percent of 0.05C capacity
100
90
80
70
60
50
40
30
Open circuit storage time in weeks
10 20 30 40 50 60 700
25°C45°C65°C
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Pulse discharge capabilities
Table 1 shows the 5, 10, 20 and 30-second pulse discharge numbers for these batteries
to 7.2V at 25ºC (77ºF). Sufficient time must be given between successive discharges to
allow the terminals to cool down. Also, fully charged batteries will meet these.
Battery Pulse discharge in amps to 7.2V
5 sec. 10 sec. 20 sec. 30 sec.
PC310 TBA TBA TBA TBA
PC535 535 465 410 380
PC545 545 495 420 380
PC680 680 595 525 400
PC625 625 545 480 450
PC925 925 870 765 675
PC1200 1,200 1,090 900 825
PC1700 1,700 1,540 1,355 1,195
PC2150 2,150 1,985 1,750 1,600
PC2250 2,250 2,075 1,775 1,675
Table 1: Pulse discharge of ODYSSEY batteries
ODYSSEY STORAGE AND DEEP DISCHARGE RECOVERY
Figure 2 shows the relationship between open circuit voltage (OCV) and state of
charge (SOC) for the ODYSSEY battery.

CHARGING ODYSSEY BATTERIES
Charging is key to the proper use of a rechargeable battery. Inadequate or improper
charging is a common cause of premature failure of rechargeable lead acid batteries.
(A) Selecting the right charger for your battery
Qualifying chargers for your ODYSSEY battery is a simple two-step process.
Step 1 Charger output voltage
Determining the charger output voltage is the most important step in the charger
qualification process. If the voltage output from the charger is less than 14.2V or more
than 15V for a 12V battery do not use the charger. For 24V battery systems the
charger output voltage should be between 28.4V and 30V. If the charger output
voltage falls within these voltage limits when the charge current starts dropping,
proceed to Step 2; otherwise pick another charger.
Step 2 Charger type - automatic or manual
The two broad types of small, portable chargers available today are classified as
either automatic or manual. Automatic chargers can be further classified as those that
charge the battery up to a certain voltage and then shut off and those that charge the
battery up to a certain voltage and then switch to a lower float (trickle) voltage.
An example of the first type of automatic charger is one that charges a battery up to
14.7V, then immediately shuts off. An example of the second type of automatic
charger would bring the battery up to 14.7V then switch to a float (trickle) voltage of
13.6V; it will stay at that level indefinitely. The second type of automatic charger is
preferred as the first type of charger is likely to undercharge the battery.
WARNING: If using a wheeled service garage charger, DO NOT use any setting above
20A as they typically have voltages in excess of 15V at current settings above 20A
A manual charger typically puts out a single voltage or current level continuously and
has to be manually switched off to prevent battery overcharge. Should you choose to
use a manual charger with your ODYSSEY battery, do not exceed charge times
suggested in Table 3 below.
Charger amps Battery model Time to full charge
PC310
6 - 10 PC535 8 – 10 hrs.
PC545 8 – 10 hrs.
PC625 12 – 14 hrs.
PC680 14 – 16 hrs.
15 –20 PC925 8 – 10 hrs.
PC1200 12 – 14 hrs.
PC1700 14 – 16 hrs.
PC2150 14 – 16 hrs.
PC2250
Table 3: Suggested charge times for ODYSSEY batteries
Concluding remarks
We believe there is no other sealed-lead battery currently available commercially that
can match ODYSSEY battery for sheer performance and reliability. We hope that the
preceding material will help the reader arrive at the same conclusion.
Publication No: US-ODY-UG-001 - February 2005www.odysseyfactory.com 7

WARRANTY: FULL 2-YEAR AND 3-YEAR REPLACEMENT
ODYSSEY Batteries of EnerSys Energy Products Inc. (seller), warrants its batteries to be free of defects in material and workmanship.
This warranty is effective for 2 years in powersports applications and 3 years in automotive/commercial/industrial applications from the date of
purchase with original receipt; 2 and 3 years respectively from manufacturer’s shipping date if no original receipt is available; or within 400
cycles to 80% depth of discharge, whichever occurs first. Within the warranty period, the battery will be replaced free of charge if adjustment
is necessary due to defect in material or workmanship (not merely discharged). Simply return the battery to any authorised ODYSSEY dealer
with the original receipt for a replacement. This warranty may vary from country to country; contact your appropriate sales region for
confirmation.
GENERAL PROVISIONS
A. Seller has no obligation under the limited warranty set forth above in the event the battery is damaged or destroyed as a result of:
Willful abuse or neglect or if the top decorative cover has been removed.
Natural forces such as wind, lightning, hail; damage due to fire, collision, explosion, vandalism, theft, penetration, or opening of the battery
case in any manner.
Overcharging, undercharging, charging or installing in reverse polarity, improper maintenance, allowing the battery to be deeply
discharged via a parasitic load or mishandling of the battery such as but not limited to using the terminals for lifting or carrying the battery.
Failure to properly install the battery or lack of metal jacket for high temperature or vibration applications.
Normal deterioration in the electrical qualities or the acceleration of such deterioration due to conditions that accelerate such
deterioration.
If the battery is used for any application that requires higher cranking power or a greater reserve rating than the battery is designed to
deliver or the battery capacity is less than the battery capacity specified by the vehicle manufacturer or the battery is otherwise used in
applications for which it was not designed.
B. To obtain warranty service:
1. Return battery to any authorised ODYSSEY wholesaler or dealer.
2. If the battery is determined to be defective for material or workmanship under terms of the warranty, it will be replaced.
THIS LIMITED WARRANTY IS IN LIEU OF, AND SELLER DISCLAIMS AND EXCLUDES, ALL OTHER WARRANTIES, STATUTORY, EXPRESS OR
IMPLIED, INCLUDING, WITHOUT LIMITATION, ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE THAT
WOULD OTHERWISE BE IN EFFECT FOR LONGER THAN THE EFFECTIVE WARRANTY PERIOD. SELLER’S EXCLUSIVE LIABILITY FOR BREACH OF
WARRANTY SHALL BE TO REPLACE THE BATTERY WITHIN THE EFFECTIVE WARRANTY PERIOD. IN NO EVENT SHALL SELLER BE LIABLE FOR
ANY LOSS OR DAMAGES OF ANY OTHER KIND, WHETHER DIRECT, INCIDENTAL, CONSEQUENTIAL, EXEMPLARY, SPECIAL OR OTHERWISE
NOR SHALL SELLER BE LIABLE FOR ANY REMOVAL OR INSTALLATION EXPENSE, OR THE LOSS OF TIME OR PROFITS.
Some countries and/or states do not allow limitations on how long an implied warranty lasts or the exclusion or the limitation of incidental or
consequential damages, so the above limitations may not apply to you. This warranty gives you specific legal rights which may vary from
country to country and/or state to state.
Website: www.odysseyfactory.com
Contact:
EnerSys Energy Products Inc.
617 North Ridgeview Drive,
Warrensburg,
MO 64093-9301, USA
Tel: [phone]
Fax: [phone]
Global Headquarters
P.O. Box 14145
Reading, PA 19612-4145, USA
Tel: [phone]
[phone]
Fax: [phone]
Regional Sales
EnerSys Limited
Rake Lane,
Clifton Junction,
Manchester M27 8LR UK
Email: odyssey[email protected]
Tel: [phone]
Fax: [phone]
Enersys Australia Pty Ltd
12 Jellico Drive,
Scoresby, Melbourne,
Victoria, Australia 3179
Tel: + 61 (0)39 763 7083
Fax: + 61 (0)39 763 9751
Publication No. US-ODY-UG-001 - February 2005 - Subject to revisions without prior notice