Powerline 6-85F-25S User manual

Solar Battery
Solar Battery Solar Battery
Solar Battery
User’s Manual
User’s ManualUser’s Manual
User’s Manual
POWERLINE
POWERLINEPOWERLINE
POWERLINE
PV
PVPV
PV
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--
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1
11
1
SolarUM.2/05.Rev.0

Table of Contents
Precautions ................................................................................................... 2
Installation ..................................................................................................... 3
Adding Water................................................................................................. 5
Hydrometer.................................................................................................... 6
Voltage .......................................................................................................... 6
Specific Gravity ............................................................................................. 8
Record Keeping............................................................................................. 8
Equalize Charge............................................................................................ 9
Sulfated Batteries .......................................................................................... 9
Battery Characteristics ................................................................................ 11
Diagrams ..................................................................................................... 12
Figures ........................................................................................................ 13
Troubleshooting........................................................................................... 14
Specifications .............................................................................................. 15
Maintenance................................................................................................ 16
Records ....................................................................................................... 17

PRECAUTIONS 2
NEVER smoke or produce a spark in the battery area.
When performing battery maintenance wear safety glasses, rubber gloves and
protective clothing.
When using a hydrometer avoid letting the rubber tube shake as this can cause
drops of electrolyte to splash onto your clothing or into your eyes. Store your
hydrometer in a clean dry place.
DO NOT OVERFILL Excessive water may spill out while battery is charging.
USE ONLY DISTILLED WATER! Using tap or well water will void your warranty.
DO NOT let foreign objects enter the cells.
INSTALLATION
STEP 1 Acquire the following safety items:
Safety glasses or face shield
Acid resistant apron
Insulated 7/16 wrench
Insulated ratchet with 7/16 socket
1 gal. neutralizing agent (1# baking soda to gal. water,
mix this solution thoroughly)
Rubber gloves
NOTE: Wrapping your tools with several layers of electrical tape will reduce the
hazard of shorting from cell to cell. You should also remove any jewelry
that may be at risk of shorting.

INSTALLATION – Continued 3
STEP 2 Inspect the battery and tray for evidence of damage, if damage has
occurred file a claim with the carrier immediately. If you see liquid on the
top of the cells pour some neutralizing agent into a small container and
apply with a clean paint brush. Be extra careful not to get any of this
agent into the cell. Apply this agent to the terminals as well as the cell
tops then rinse with clear water and wipe dry.
CAUTION: If you should get battery acid in your eyes, flush with clear water for 15
minutes and seek medical attention. DO NOT use the neutralizing agent
in your eyes.
STEP 3 Remove the tray lid by tapping one hinge back into the lid hinge; or
remove the internal hex-head bolts.
STEP 4 Remove the buss bars.
STEP 5 Connect the cell lifting strap into the holes of the terminals and lift the
cells out of the tray. If the clevis on the cell lifting strap will not slide over
the terminal slightly spread the clevis.
NOTE: If you move the battery fully assembled skip the remaining steps.
WARNING: Do not let the lid fall onto the cells as this could cause shorting from
terminal to terminal.
CAUTION: These cells can be extremely heavy, a come-along or block and tackle
may be needed to do the lifting. Do not try lifting these cells by yourself.
Serious injury could occur.

INSTALLATION – Continued 4
WARNING: The weight inside the plastic cells will cause the sides to bulge when
removed from the tray. This is normal, however, use caution when
handling the cells. Any pressure on the sides will cause the cells to
“breathe” and can release small droplets of electrolyte in the area of the
cap. Placing a rag over the vent cap will reduce this hazard.
NOTE: As you remove the cells from the tray you may notice the electrolyte
level is very low. DO NOT add water to the cells, this condition is
normal. As soon as the battery is reassembled, charge the battery at 2%
of its rated capacity. After approximately 2 hours, the electrolyte level
will return to normal. If the electrolyte level does not rise as expected,
contact your dealer.
STEP 6 Neutralize the sides of the cells and the steel tray. Rinse and dry
thoroughly.
STEP 7 Move the steel tray to the desired location.
STEP 8 Install the cells back into the tray using the diagram on page 12 to
ensure the cells are correctly installed. The cells must be completely
seated in the tray to properly install the cell interconnects. All plastic
spacers MUST be reinstalled when the battery is assembled.
STEP 9 Referring to the diagrams on page 12 or 13, install the nuts and bolts in
the exact pattern as shown. If your installation requires the inverter
connections to be on the opposite side of what is shown, turn the book
over and proceed. Torque all bolts to 115-135 inch lbs.
WARNING: Never allow tools or other conductive objects to make contact with
two or more battery terminals.

INSTALLATION – Continued 5
STEP 10 Install the lid by taping the hinge pin back into the can hole. When you
install the lid you have a choice of where the hinges are located. Some
lid hinges use an internal hex head bolt, use an Allen wrench to remove
and replace the lid.
ADDING WATER
Fill to ¼” from the bottom of the cap (throat). A flashlight will make adding water
much easier. A certain amount of water loss is normal in all batteries, and must be
replaced at regular intervals with distilled or deionized water. Over filling is one of
the most common errors made during batter maintenance and will cause gradual
lowering of the specific gravit and a subsequent loss of capacit , corrosion to the
can and intercell connectors. Add water after the batter is done charging and
after taking h drometer readings. If the batter is subjected to freezing
temperatures it is a good idea to add water when the batter is reaching
approximatel ¾ charged or 1 hour before ending an equalize charge. It can take
up to several da s for the fresh water to mix with the rest of the acid. This fresh
water could freeze before mixing with the electrol te.
WARNING: Do NOT over fill. Do NOT use tap or well water. They can contain
small amounts or nickel, iron, manganese, copper, chlorine, nitrates, etc.
These and other minerals can seriously affect battery life.

HYDROMETER 6
Insert the rubber tip into the cell but not into the electrolyte. Squeeze the bulb and
lower the rubber tip into the electrolyte and release the pressure from the bulb. The
barrel will fill up and the float will rise. It is very important for the float to be freely
suspended in the electrolyte. Gently move the hydrometer back and forth until the float
is not in contact with the barrel, where the numbers on the float intersect with the top of
the electrolyte, this is the specific gravity. See the following section for interpreting your
hydrometer readings. With the rubber tip in the cell, but not submersed into the
electrolyte, squeeze the bulb and drain the electrolyte back into the cell. Wipe dry any
spilled electrolyte.
WARNING: Always wear protective clothing and eye/face protection when working
around batteries. If you should get acid in your eyes or on your skin,
flush with clear water for 15 minutes and see a physician. Do not use
neutralizing agent in your eyes.
VOLTAGE
OPEN CIRCUIT READINGS There is a definite relationship between the cell
voltage and the specific gravit of a cell that is on open circuit (no charging or
discharging). These open circuit voltage readings are useful in determining
uniformit . A full charged batter on open circuit, with a specific gravit of 1.260
– 1.280 will read 2.10 volts per cell to 2.12 volts per cell at 77˚ F. This spread of
.02 vpc is considered normal for a new batter . As the batter ages, the spread will
increase to about .03 vpc.
DOD (Depth of Discharge) Total Battery Volts
12 v / 24 v / 48 v Specific Gravity
0% (Full Charged) 12.78 / 25.56 / 51.12 1.275 – 1.285
50% (Half Discharged) 12 / 24 / 48 1.205
80% (Considered Dead) 10.5 / 21 / 42 1.175
100% (Over Discharged) 9.3 / 18.6 / 37.2 1.140
NOTE: You must take the electrolyte temperature into consideration when using
voltage readings (see Pg. 13).

VOLTAGE – Continued 7
FULLY CHARGED VOLTAGE READINGS On-charge voltage readings are most
informative and are good indicators of battery condition. These readings should be
taken when the battery is approaching full charge with 2% of the battery capacity
flowing into the battery. New batteries, when fully charged and 2% of the battery
capacity flowing into the battery, will have cell voltages between 2.55 – 2.65 vpc.
Older batteries with the same circumstances will have voltages about 2.45 – 2.55 vpc.
Multiplying the battery capacity times .02 will give you 2% of capacity.
Example: 6-85F-17S 845 x .02 = 16.9 amps.
VARIATIONS IN ON-CHARGE VOLTAGE If all cells of a battery show similar full-
charge voltages, they are equally healthy. The uniformity and value of the individual
cell voltage readings vary with the overall condition of the battery. A battery with an on-
charge voltage of 2.45 to 2.50 volts per cell has more uniformly healthy cells than a
battery having an on-charge voltage spread of 2.40 to 2.50 volts per cell. The battery’s
age and service duty must be considered in the interpretation of the on-charge voltage
readings. An example would be an older battery which has on-charge cell voltage
readings of 2.45 volts to 2.65 volts. The reason may very well be that the inside cells
operate at higher than average temperatures causing higher local action, which would
result in lower voltage. Regular equalize charging will compensate for the higher self-
loss of the inside cell. Any wide spread in on-charge voltage that could not be
attributed to the battery’s service life or age is a sign that something is wrong and
attention is necessary. Some cause of abnormally wide spread or charge voltages are:
1. Abnormal temperature differential
2. Internal shorts
3. Acid loss causing over-discharge
4. Insufficient charging
5. Insufficient equalize charging
General Settings for Trace Inverter/Charger
12 Volt 24 Volt 48 Volt
Bulk 14.8 29.6 59.2
Equalize 15 – 15.5 30 – 31 60 – 62
Float 13.5 27 54
These voltage settings are ball park settings that will work for most systems. If you find your specific
gravity is not reaching 1.275-1.285 raise these settings by .1 volt increments until the specific gravity
readings indicate a fully charged battery. If the battery uses an excessive amount of water or is
overheating, lower the settings by .1 volt increments until the overcharge is removed.

SPECIFIC GRAVITY 8
The standard fully charged specific gravity for the HAWKER PV-1 Solar Battery is
1.275 – 1.285 at 77˚ F (see Fig. 4 and Fig. 5 on page 14) and the 100% discharged
gravity is 1.140. Since the acid content of the electrolyte decreases linearly as the cell
is discharged, the decrease in gravity is directly proportionate to the amount in
ampere-hrs taken out. The specific gravity at any point in the discharge indicates the
depth of discharge, and can be translated into ampere-hrs taken out. Knowing that the
fully charged gravity is 1.280 and the final specific gravity is 1.140 we can find our state
of discharge.
EXAMPLE: Assume the specific gravity is 1.180 that is 100 points below the
fully charged specific gravity of 1.280. With a difference of 140 points from 100%
charged to 100% discharged we can divide 100/140 = 71% discharged. Use this
formula to help keep your Amp/Hr meter synchronized with your battery. (See Fig
1 on Page 14)
WARNING: All lead-acid batteries are considered discharged when 80% of the
capacity has been removed. NEVER remove more than 80% of the
battery capacity.
RECORD KEEPING
This simple task is required for our warrant and will be of great assistance in
determining the health of our batter . Record keeping is the single most
important tool in good batter maintenance. As the batter ages ou can see
trends, spot possible problems before the become permanent and make an
adjustments to our charging s stems. Without records it is almost impossible to
know how our s stem is functioning. While instrumentation in Renewable Energ
has made leaps and bounds, the are onl another tool in the proper operation of
our batter . B using the records and instrumentation together, our batter
s stem can provide ou with ears of trouble-free service.

EQUALIZE CHARGE 9
The term “equalize” simpl means a controlled overcharge. This procedure is used
to adjust the difference between cells that develop due to temperature variations
within the batter , manufacturing, and c cling of the batter . The equalize charge
will also help scrub off sulfate particles that tend to build up on the batter ’s
positive plate. When to equalize: If a cell has a .020 difference in specific gravit or
at least once a month. How to equalize: Generall ou continue the bulk charge for
an additional 3 hours after the batter has become full. The equalize charge rate
should be approximatel 2% of the batter capacit . This will tend to raise the
batter voltage 1-1.5 volts above the bulk setting. Ensure that an sensitive loads
can accept this higher voltage.
SULFATED BATTERIES
All lead acid batteries sulfate when discharged. The active material must convert to
lead sulfate in order for the cells to produce energ . The term sulfated batter
means that the batter has developed abnormal sulfate and has its capacit
reduced as a result. The most common cause of sulfation are:
1. Under charging or neglect of equalize charge
2. Standing in a partially or completed discharged condition
3. Low electrolyte level
4. Adding acid
5. High specific gravity
6. High temperature
WARNING: Do not let your battery stand in a discharged state for more than 24
hours or when temperatures are below freezing.

SULFATED BATTERIES – Continued 10
Cells of a sulfated battery give a low specific gravity and voltage reading and the
battery will not become fully charged after a regular equalize charge. Before assuming
that the battery is sulfated, rule out the possibility that low specific gravity may be due
to acid loss. If the sulfation has not progressed too far, it may be possible to return the
battery to a serviceable condition by paying careful attention to the following:
1. Neutralize, wash and dry the battery.
2. Add water to the proper level
3. Charge the battery at 2% of its capacity using the 6 hr. rate until 100% of the
battery’s capacity has been restored.
Example: 6-85F-23S
1160 A/H x .77 = 893 A/H at the 6 hr. rate
893 A/H x .02% = 17.86 amps
17.86 amps x 50 hrs = 100% of the 6 hr. capacity
4. Discharge the battery to 1.75 volts per cell (10.5 for 12 volt systems or 21 volts
for 24 volt systems) making sure not to allow any cells to go into reversal. Cell
reversal can be identified by very high cell voltage (3-4 volts) while on charge, or
very low cell voltage (1 volt or less) while being discharged.
5. Recharge until the specific gravity is the same for 3 hours.
6. Repeat the process until the specific gravity remains constant. If the battery gives
80% or more you have succeeded; if not, replace the battery.

BATTERY CHARACTERISTICS 11

DIAGRAMS 12

FIGURES 13
Specific Gravity vs.
Percent Discharged
% Discharged
1.280
1.260
1.240
1.220
1.200
1.180
1.160
1.140
1.120
0 10 20 30 40 50 60 70 80 90 100
Specific Gravity @ 77˚ F
Freezing Points of
Battery Electrolyte
Specific
Gravity Centigrade
Fahrenheit
1.000
1.050
1.100
1.125
1.150
1.175
1.200
1.210
1.220
1.230
1.260
1.270
1.280
1.290
0
-3.3
-7.7
-10
-15
-20
-26
-31
-36
-41
-57
-62
-66
-69
+32
+25
+18
+14
+5
-4
-15
-23
-33
-42
-71
-80
-87
-92
Cell Specific
Gravity
Temperature
Correction
Temp.
Fahrenheit
Correction
Factor
39-41
42-44
45-47
48-50
51-53
54-56
57-60
61-63
64-66
67-69
70-72
73-75
76-78
79-81
82-84
85-87
88-91
92-94
-.012
-.011
-.010
-.009
-.008
-.007
-.006
-.005
-.004
-.003
-.002
-.001
0
+.001
+.002
+.003
+.004
+.005
Cell Voltage Correction Factors
Electrolyte
Temperature
˚F
Cell Voltage
Correction To
Be Subtracted From
Measured Volts
Electrolyte
Temperature
˚F
Cell Voltage
Correction
To Be Added
To Measured Volts
49-51
52-54
55-57
58-60
61-63
64-66
67-69
70-72
73-75
-0.09
-0.08
-0.07
-0.06
-0.05
-0.04
-0.03
-0.02
-0.01
76-78
79-81
82-84
85-87
88-90
91-93
94-96
97-99
100-102
None Needed
+0.01
+0.02
+0.03
+0.04
+0.05
+0.06
+0.07
+0.08
Temperature Effect
On Batteries
Electrolyte
Temperature
˚F
Percent
Capacity
77˚
60˚
50˚
40˚
30˚
100%
95%
91%
87%
81%

TROUBLESHOOTING 14
PROBLEM PROBABLE CAUSE REMEDY
Battery not
performing as
expected.
1. Battery is undersized
2. Battery not fully charged
3. Weak or defective cells
4. Grounds or shorts
5. Phantom loads in system
6. Battery is spent
1. Replace with a larger battery
2. Check charger and controller
3. Perform a load test
4. Clean battery and all connections in
the system
5. Find and eliminate loads
6. Replace battery
Battery
overheats on
charge.
1. Improper equipment settings
2. Malfunction of charging equipment
3. Battery too deeply discharged
4. High resistance connection
5. Low electrolyte level
6. Battery room too warm
7. Weak or defective cells
8. Battery is spent
1. Adjust charging equipment
2. Verify charging equipment output
3. Limit discharge to 80% DOD
4. Check for hot connections
5. Water battery to correct level and
allow to cool and recharge
6. Provide cooler battery room
7. Repair or replace battery
8. Replace battery
Battery
overheats on
discharge
1. Excessive load
2. Battery not full recharged
3. Battery over discharged
4. Battery room too warm
1. Reduce loads. Need larger battery
2. Let battery cool. Do a load test
3. Limit discharge to 80% DOD
4. Provide cooler battery room
Low
electrolyte
level
1. Lack of watering
2. Frequent overcharging
3. Spilled electrolyte
4. Cracked or broken jars
1. More care required
2. Adjust/check charging system
3. Add water, equalize and adjust
specific gravity (contact dealer)
4. Replace jars
Unequal cell
voltages
1. Overdischarging
2. Acid loss due to over-watering or
spillage
3. Corroded or dirty tops
4. Grounds in battery
5. Impurities in electrolyte
6. Battery used infrequently
7. Weak or defective cells
8. Lack of equalize charges
1. Give equalize charge
2. Give equalize charge and adjust
specific gravity
3. Neutralize and clean tops
4. Clean battery
5. Use only distilled water
6. Deep discharge and equalize
7. Repair or replace battery
8. Equalize more often
Unequal
Specific
Gravity
1. All of the above
2. Recently added water
3. Improper gravity adjustment after cell
replacement
1. All of the above
2. Gassing will mix new water
3. Adjust specific gravity(see your
dealer)

TROUBLESHOOTING 15
Model #
(12 Volt)
Rated
Amp Hrs @
20 hr. Rate
Dimensions
LxWxH in
Inches @ 12 V
Weight in
Lbs.*
Short Circuit
Ratings Amps
@ 104˚ F
6-85F-17S 845 38.25 x 6.94 x 25 666 9,600
6-85F-19S 950 38.25 x 7.69 x 25 738 10,800
6-85F-21S 1055 38.25 x 8.44 x 25 816 12,000
6-85F-23S 1160 38.25 x 9.19 x 25 888 13,300
6-85F-25S 1270 38.25 x 9.94 x 25 966 14,400
6-85F-27S 1375 38.25 x 10.69 x 25 1044 15,600
6-85F-29S 1482 38.25 x 11.44 x 25 1116 16,800
6-85F-31S 1585 38.25 x 12.19 x 25 1194 18,000
6-85F-33S 1690 38.25 X 12.94 x 25 1272 19,200
*Weights +/-5%
Warranty 10 years
Cycles to 80% DOD 2100 over 10 years
Battery Type Flooded Lead-Acid
Positive Plate Tetrafluoroethylene (Teflon®)/Lead Antimony)
Post-to-Cover Seal Burned Post to Cover
Cell “Jar” Material Injection Molded Polypropylene
Cell Cover Material Polypropylene
Tray Material Epoxy Coated Steel
Intercell Connectors Lead Plated Copper Rated @ 700 Amps
Specific Gravity @ 77˚ F 1.285-1.275 Fully Charged 1.160 80% Discharged
Model # Breakdown
Example: 6-85F-17S
6 cells per Tray
85 amps per positive plate
F represents Powerline
17 plates total (8 pos. & 9 neg)
PV-1 Solar Battery
Photo is a 12-85F-13 battery.

MAINTENANCE 16
WEEKLY
1. Record hydrometer reading of pilot cell (the cell with the lowest specific gravity
when you first received the battery). Once a year select a different cell to be the
pilot cell.
2. Check the water level (add as needed).
3. Record Amp/Hrs consumed.
4. Inspect connections for corrosion (clean as needed).
MONTHLY
1. Record hydrometer readings of all cells (after the battery is fully charged).
2. Check water level (add as needed).
a. If the average readings are less than 1.275 – 1.285 check all charging
sources and adjust as needed.
b. If one or two cells read 20 points more or less than the average, circle
those readings and check for improvement at next monthly reading. If the
low cells do not improve, the cells are in need of an equalize charge,
specific gravity adjustment or internal inspection.
3. Record Amp/Hrs consumed.
4. Record battery temperature.
5. Clean battery with a damp cloth. (If battery tops are wet with acid use neutralizing
agent with a clean paint brush, dry thoroughly.)
6. Equalize the battery (see Page 5).
7. Inspect connections for corrosion (clean as needed).
YEARLY
1. Torque all terminal bolts.

RECORDS 17
ENTERING DATA IN THE WEEKLY FORMS
It is essential that you label each cell for these records to aid in the operation of your battery. This
form is designed to enter general battery information on a weekly basis and will, at a glance, show
any abnormalities in the battery’s health.
Select a pilot cell, this should be the cell with the lowest specific gravity after you do your initial
charge after installation. It is suggested that the pilot be rotated annually to a different cell in the
battery.
Step 1. Enter the date.
Step 2. Enter the pilot cells voltage.
Step 3. Enter the specific gravity of the pilot cell.
Step 4. Check your A/H meter and enter the amp/hrs reading.
Step 5. Enter the cell temperature.
Step 6. Enter a “W” if water has been added in the previous week. Enter an “E” if the
battery has been equalized in the previous week. Enter a “C” if the battery was
cleaned in the previous week.
ENTERING DATA IN THE MONTHLY FORMS
Once a month enter the specific gravity and cell volt ages of all cells in the appropriate columns. If
your battery has more than 12 cells you can identify these cells as “AA, BB, CC” , etc.

WEEKLY
DATE CELL
VOLTAGE SP. GR. A/H USED CELL TEMP. W.E.C.

WEEKLY
DATE CELL
VOLTAGE SP. GR. A/H USED CELL TEMP. W.E.C.