Deep Cycle Battery

Safety.First.
Battery Handling, Maintenance & Test Procedures
Crown deep cycle batteries employ The chemistry and plate design of deep cycle
a low-maintenance design. They batteries are totally different than that of automotive

do require periodic maintenance starting batteries. The grid metal used in the deep
cycle battery plate is specifically formulated to
and effective charging service to
increase the adhesion of high-density
ensure dependable service life.
active paste material. This provides
The purpose of this service guide the best available running time,
is to help you understand the cycle life and charge acceptance.

characteristics, operation and care

of the batteries in your equipment

so that all of their advantages may

be fully realized.

Crown Battery’s heavy-duty plate design also protects against the

stress of challenging Electric Vehicle (EV), motive power and RE (RE)
applications – which includes vibration, heat and overcharge.
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 Inspection & Handling
1. Do not allow batteries in your equipment to tip or operate at
a severe angle in any direction. This would allow the battery
electrolyte to push through the battery vent assembly.
2. Charge the batteries in your equipment in a
well-ventilated area.
3. Upon receipt of your equipment, examine the batteries for
signs of wetness or impact (which may indicate damage in
shipment or that the batteries were tipped beyond a
45° angle during transit).
4. If there is evidence of damage – notify Crown Battery or
the OEM supplier to make a damage report.
5. Charge the batteries before placing the batteries in service.
Simply connect the battery charger to your machine’s
charging port and allow it to run until it automatically
shuts off.

Operating Guidelines
Deep cycle batteries supply all the power used in EV, motive power
or RE system applications. One full cycle represents a full battery
recharge followed by a complete battery discharge (as specified by
the OEM). Battery life is usually measured in cycles – but in practical
terms, your batteries should work well for three years from the
beginning date of service.
However, battery maintenance and charging procedures will
either prolong or shorten battery life, depending upon how well
recommended practices are followed.

Other Factors That Affect Battery Life and Performance:

u Batteries are rated in ampere-hours (Ah) and are designed to perform u Under normal circumstance the temperature of the battery electrolyte
a specific workload within an established period of time. Increasing must not exceed 110° F (43°C). If the battery is continuously operated
either and/or both of these will over-discharge the batteries and result at or above this point the service life of the battery will be severely
in shortened life. diminished. Under normal conditions, battery electrolyte condition
u Limit discharging the batteries beyond 1.75 volts per cell – or 1.125 should range from 60° to 100° F (15° to 38°C). After charging, the
specific gravity per cell. 1.75 volts per cell corresponds to end-point battery should be allowed to cool-down or rest from 6 to 8 hours
voltages of 5.25 volts for 6-volt batteries, 7 volts for 8-volt batteries before the next discharge cycle begins.
and 10.5 volts for 12-volt batteries. u If a battery is ever hot to the touch, allow it to cool to ambient
u Batteries should always be recharged immediately following a temperature before charging or discharging.
complete discharge period. Never allow batteries to remain in a fully u Keep battery connectors and cabling in good condition. When
discharged condition, otherwise permanent damage will result. disconnecting the battery connector from the equipment, pull on the
u If daily or routine equipment operation results in only partial discharges connector – not the cable. Damage to the connectors and/or cables
(40% or less) and specific gravities are 1.225 or higher, recharging will result in poor battery performance.
may be deferred to the next day, providing the workload is not expected
to increase. Generally, user experience will determine the frequency of
charging service under these circumstances.
Renewable Energy Charging Systems
To maximize performance and life batteries should be recharged more frequent equalization occurring for battery systems routinely
fully after each discharge period. To verify full recharging, discharged below 50% of their rated capacity. Please refer to the
regularly monitor individual battery voltage and specific gravity. following chart for additional charge control setting information:
As a general rule, the total input amperes from your RE charging System Voltage
source should be between 10% and 20% of the total ampere- Voltage Setting 6V 12 V 24 V 36 V 48 V
hours (20 Hour Rating) of the battery system capacity. Many RE Daily Charge (Absorption) 7.3 14.5 29.0 43.6 58.1
Equalize 7.7 15.5 31.0 46.4 61.9
charge controllers have adjustable equalization settings that ensure
Float 6.8 13.5 27.0 40.5 54.0
batteries are regularly restored to full capacity. Batteries used in RE
Contact Crown Battery’s technical support department for additional charging
systems should be equalized every thirty days at a minimum – with application information.

Watering Service
Deep cycle batteries begin service consuming relatively low u Never charge
amounts of water. In electric vehicle, motive power or RE service, batteries if the
the real need to add water to batteries may vary from weekly service battery plates
to monthly service depending upon the operating environment and are found to
other external factors. As batteries age they will use more water, be uncovered/
and in warmer climates batteries will require more frequent service. un-submerged
in electrolyte.
Equipment owners and users must be vigilant in performing regular
If this condition
watering service to ensure premium performance and life.
is detected before
There are two conditions when watering can be charging service, fill the
harmful to your batteries: battery only until the top of the
q Over-Watering q Under-Watering battery plates are covered with liquid.

Over-Watering dilutes the sulfuric acid levels inside the battery – Many Crown deep cycle batteries feature the PROeye indicator that shows
which results in poor battery performance. Under-Watering batteries users when watering service is required. When the color of the eye is:
leads to a service-related overcharge condition, which q Green = No water service is required
will shorten battery running times and life.
q Clear or White = Watering service is required
The PROeye is an indicator only – and is designed to aid users with
determining when individual cell inspection and/or watering service
is required. Because watering service is most effective at the
completion of charging service – the PROeye should be inspected
at the completion of charge or before the start of duty cycle. Contact
Crown Battery’s technical department for more information regarding
You can prevent watering-service related problems by using the this product feature.
illustration shown above as a reference point. Maintain battery liquid
levels above the top of the battery plates – but no higher than the
battery cover vent well. Never fill batteries to the brim of the cell or to
SAFETY PRECAUTIONS:
1. CAUTION: All lead-acid batteries generate highly flammable hydrogen
a point where they overflow. gas. If ignited, the gas may explode violently. When working near
batteries, always wear safety glasses, do not smoke or use open flame
Several other rules apply when watering: near the batteries, remove watches and jewelry, and avoid causing
u USE ONLY DISTILLED or DE-MINERALIZED WATER. sparks with tools.
2. Battery electrolyte is corrosive and can cause blindness or severe burns.
u Never add battery acid, commercial additives or other foreign If exposed to battery electrolyte, immediately flush with water and seek
material to the batteries. medical attention.
3. The batteries in your equipment are electrically live at all times. Keep the
u Watering service should occur only after charging service top of the batteries clean and dry to prevent ground shorts and corrosion.
is completed. Watering before charging service will result in 4. Do not tip a battery beyond a 45° angle in any direction. This would allow
overflow of the battery’s electrolyte – causing a dangerous battery electrolyte to push through the battery vent assembly.
chemical spill condition and loss of battery capacity.
Preventative Maintenance
u Battery covers and terminals should be kept clean, dry and free soda and water mixed in the proportion of one pound of baking soda
of corrosion. Battery vent caps must be secured to the batteries to one gallon of water. When the electrolyte is neutralized, wipe the
during use and charging period. Remove vent caps only to inspect affected area with a water-moistened cloth to remove all traces of
electrolyte levels or specific gravities. soda.
u When batteries or terminals require cleaning, use only u Inspect cable-to-terminal connections to ensure connections are
biodegradable cleaner-neutralizer solutions that can be safely tight and free of corrosion. Battery cables must be intact with no
applied and disposed of through a common sanitary sewer. Other exposed wires.
chemical-based solutions are often dangerous, ineffective and u Preventative maintenance practices should include periodic
cannot be disposed of in an environmentally safe manner. inspection of battery specific gravity and open circuit voltage. An
u If electrolyte is spilled onto batteries or the battery compartment imbalance of specific gravity and open circuit voltage is usually a sign
area, neutralize it with a cloth moistened with a solution of baking of improper charging, service infrequency, or a bad cell condition.

Connecting Multiple Batteries

Crown deep cycle batteries are available in various BCI group sizes, voltages and electrical capacities. Certain systems require
the installation and connection of multiple batteries to accommodate minimum voltage or capacity specifications to ensure
expected performance. Users and technicians should always confirm that batteries are oriented in proper position according
to battery terminal polarity – as indicated by the raised polarity mark on the battery cover. Cables and connectors should be
secured with the appropriate terminal hardware and tightened to the torque values specified by Crown Battery.

Series Connection: Parallel Connection:

To increase voltage, connect batteries in “series” as shown: To increase electrical capacity, connect the batteries in “parallel”
as shown below:

Example: Example:
Individual Battery Voltage = 6 Volts Individual Battery Voltage = 12 Volts
Individual Battery Capacity = 250 Ah Individual Battery Capacity = 150 Ah
Series Connection Voltage = 12 Volts Parallel Connection Voltage = 12 Volts
Series Connection Capacity = 250 Ah Parallel Connection Capacity = 300 Ah

Series Connection: Series-Parallel Connection:

Single String Series Connection of twenty-four 2 Volt batteries To increase both voltage and electrical capacity, connect the
batteries in a “series-parallel connection” as shown below:

Example:
Individual Battery Voltage = 6 Volts
Individual Battery Capacity = 250 Ah
Example: Series-Parallel Connection Voltage = 12 Volts
Individual Battery Voltage = 2 Volts Series-Parallel Connection Capacity = 500 Ah
Individual Battery Capacity = 3690 Ah
Series Connection Voltage = 48 Volts
Series Connection Capacity = 3690 Ah
Charging Guidelines – EV or Motive Power Service
Original equipment systems usually include an automatic gassing level (2.37 volts per cell), and the input current is allowed
charging system for battery charging. To maximize battery life and to gradually diminish. When the input current falls to the finish rate
performance, batteries should be charged as outlined in the operating setting of 3 to 4 amperes per 100 ampere-hours (20 Hour Rating) of
instructions included with the charging equipment. In the event of a battery capacity, the charge phase will change from constant voltage
charging-related battery performance problem, consult the OEM or to constant current at 3 to 4 amperes per 100 ampere-hours (20
Crown Battery service department to seek technical support. Extra Hour Rating) of battery capacity – with a maximum charging voltage
care spent in proper charging will ensure battery performance. of 2.65 volts per cell. The charge will be terminated approximately
Battery charging equipment varies in terms of output and overall 3.5 hours from the gassing point by an approved charge termination
charging performance. For new or replacement chargers used in EV method such as DV/DT. Please note that fixed ferro-resonant
or motive power service, Crown Battery recommends electronically chargers using this profile must have finish voltages set at 2.58 volts
controlled automatic chargers that are programmed to deliver a high per cell or higher.
constant current rate of 12 to 18 amperes per 100 ampere-hours (20 Batteries should always be recharged immediately following a
Hour Rating) of battery capacity. The constant voltage phase begins complete discharge period. A weekly equalization charge – with the
after the gassing point is achieved (2.37 volts per cell). This stage of finish rate charge time extended 3 hours for a total of 6 hours from
charge will last approximately 5 hours for a fully discharged battery. the gassing point – will ensure reliable discharge time and battery
During the constant voltage phase the charger voltage is limited to the life. The charge factor of the standard recharge cycle should be
equal to or greater than 1.08 (108%), while the charge factor of the
Troubleshooting equalization cycle should be equal to or greater than 1.15 (115%). To
When properly maintained and charged, Crown deep cycle batteries will ensure optimum battery performance, total recharge time should in
provide many years of trouble-free service. However, failure to follow the all cases be limited to 10 hours.
operating and maintenance guidelines listed above may result in poor
performance or premature failure. The following addresses some of the Power off the charger before connection to the battery to avoid
typical errors in operation and maintenance: sparking. To avoid battery explosion, never charge a frozen battery
– warming the battery to room temperature before charging service
Condition Check For
begins. Charging service should be terminated if batteries become
Undercharged Battery
excessively hot or if violent gassing or discharge of electrolyte
Sulfated Battery
Cold Operating Environment occurs during charge.
(Less than 32°F / 0°C Temperature
Poor Battery Performance Reduces Usable Battery Capacity)
Defective Connectors or Cables
Low Electrolyte
Old Batteries
Defective Charge-Level Gauge
Over-filling
Unequal/Low Specific Gravities Undercharging
Overcharging
Excessive Water Service Container Leak
Old Batteries
Low Electrolyte
Odor During Charging Overcharging
Overcharging
High Temperature Battery Overworked
Opportunity Charging
 Troubleshooting
A common procedure for troubleshooting 1. Visual Inspection: Check battery age or length of service if available. Inspect
battery performance involves a battery for damage - when physical damage to the battery container or terminals is
present, replace the battery. If none, check the battery’s cell electrolyte levels. Fluid
three-point procedure: levels should be above the top of plates in all cells, and no higher than the top of the
fluid level indicator:
If the battery is sufficiently
filled with electrolyte –
proceed to step 2. If the
top of the battery’s plates
are not covered with liquid,
add water, replace vent caps and place the battery on charge. Be sure no open flame or
spark is near while the battery’s vent caps are removed from the battery.
2. Specific Gravity Inspection: Hydrometer reading of all cells should be at least
1.225 and show less than 50 points difference between high and low.
u More than 50 points difference: replace the battery.
u Less than 50 points, but some cells read less than 1.225: recharge the battery.
Replace the vent caps during recharge. Charge the battery using a properly matched
automatic charger until all cells measure a specific gravity of 1.265 to 1.275. If charging
won’t bring up specific gravity, replace the battery.

Example: Hydrometer State of Specific

Float Charge Level Gravity
1.300 1.250 1.200 1.150
CELL 6 - 1.200 CELL 6 - 1.225
CELL 5 - 1.210 CELL 5 - 1.230 100% 1.265 or Greater
CELL 2 - 1.215 CELL 2 - 1.235
CELL 1 - 1.240 CELL 1 - 1.240 75% 1.225 - 1.230
CELL 3 - 1.240 CELL 3 - 1.245
CELL 4 - 1.255 CELL 4 - 1.250 50% 1.185 - 1.190
VARIATION VARIATION
55 POINTS 25 POINTS 25% 1.140 - 1.175
BATTERY READY TO
WORN OUT LOAD TEST Discharged 1.125 or Less

3. Open Circuit Voltage and Electrical Load Test: Battery open circuit
voltage is an effective indication of battery state of charge. Determine the approximate
state of charge from the following chart:
State of 12 Volt Battery 8 Volt Battery 6 Volt Battery
Charge Level Open Circuit Voltage Open Circuit Voltage Open Circuit Voltage
100% 12.60 or Greater 8.40 or Greater 6.30 or Greater
75% - 100% 12.30 - 12.60 8.21 - 8.40 6.16 - 6.30
50% - 75% 12.10 - 12.30 8.00 - 8.21 6.00 - 6.16
25% - 50% 11.90 - 12.10 7.87 - 8.00 5.90- 6.00
0 - 25% 11.60 - 11.90 7.73 - 7.87 5.80 - 5.90
0% 11.60 or Less 7.73 or Less 5.80 or Less
Chart Assumes a Fully Charged Gravity of 1.265.

Battery Voltage Under 15 Second Load

State of Charge 12 Volt 8 Volt 6 Volt Specific Gravity
100% 12.60 8.40 6.30 1.270
75% 12.00 7.87 5.90 1.225
If the test voltage is above the minimum, return the battery to service.
If test voltage is below the minimum, replace the battery.

Electrical load testing is an effective troubleshooting technique for identifying

batteries with internal defects – but it is not an approved method for measuring deep
cycle battery capacity. For this reason Crown Battery recognizes load test results as
useful only for identifying batteries having bad cell conditions.
Batteries with less than 75% state of charge should be charged before an electrical
load test is applied to the battery. When load testing batteries, remove all battery
Crown Battery Manufacturing Co. cables, disconnecting the negative cables first. Make sure the battery terminals are
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Fremont, OH 43420-0990 For batteries having stainless threaded stud terminals, attach a lead charging post
419.334.7181 | Fax 419.334.7124 to the threaded stud terminal before testing. Using a carbon pile load tester, apply a
commercial@crownbattery.com 50 to 75 ampere load for 15 seconds; remove the load. Refer to the chart at the left to
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