• The battery is the heart of your truck• Without food and drink, even a genius can’t think• Brains and brawn - the right combination of charger and battery makes your life easier
Choosing your traction battery and charger
Traction batteries - general
ConstructionCells connected in series,each of 2 volts
SizeNumber of cellsCell lenghtCell widthCell height
A little battery chemistry
DischargeThe truck consumes current and the battery is discharged- the voltage and density decrease
ChargeMain ”bulk” charge: The battery gets the current consumed back plus...Gas phase: 5-20% extra to get the acid agitated andin equilibrium
Discharge Charge
Voltagedecreases
Voltageincreases
Platessulphate
Densitydecreases
Platessulphate
Sulphatesare
dissolved
Densityincreases
Sulphatesare
dissolved
Pause charging
ImportantThe battery must not emit gasduring pause charging
Fully charged
Charging Gassing Charging
80%
Deep discharged
Pause Pause
80% is the correctdepth of discharge
Self-discharge
ImportantA battery that is not used for a while mustbe fully charged when it is stored
5-7% self-discharge per month, depending on the battery’s age
If a battery is stored for an extended period of time, it must be charged every now andagain, every three months, for example
When the battery is cold,the voltage and density
are different to what youare used to
Cold stores
But the voltage value must always be 0,84 higher than the
density value
Choosing your battery
Normal operationNormal operating timeNormal charging timeMost used batteryDischarge depth… max. 80%
Standard battery
Choosing your battery
Normal operationShort charging timePause chargingMinimal heat generation during chargingDischarge depth… max. 80%
Acid circulation battery
Choosing your battery
Hard operationStiff voltageHigh energy gainTwo or three-shift operationDischarge depth… max. 80%
CSM (Copper Stretch Metal) battery
Choosing your battery
Light operationLess capacityNo topping up with waterNo acid overflowDischarge depth… 70-75%
Dryfit battery, VRLA maintenance-free
Life factors
Battery life5-6 years or around 1500 (1200) cycles in normaloperation with one outlet and a discharge depthof max. 80% (70-75%) per day
ImportantOver 80% (70-75%) discharge depth constitutes a deep discharge and invalidates the battery warranty
Discharge depth and life:80% (70-75%) discharge produces 100% life90% discharge produces approx. 75% life
CyclesIn number
1500
60% 70% 80% 90% Discharge depth in pct.
Difinition of a cycleA cycle is a discharge followed by a charge.The more cycles a battery undergoes in a24-hour period, the shorter its life in termsof time
Life factors
What affects the lifetime of a battery?Deep discharges: Max. 80% depthOver consumption: Max. 80% of capacityHigh temperatures: Max. 500C in the acidOvercharging: Burns the battery outUndercharging: Sulphates the batteryMaintenance: Incorrect acid level, dirt, faults, etc.
Why is too much current used?Battery too smallDriving and lifting at the same timeThe truckdriver likes to think he’s a racing driverTruck faults (wear and tear, brakes sticking, dirt in wheels)Too much additional equipmentIncorrect tyre type, ramp driving, driving surface
When does a battery sulphate?If it is left unchargedIf it is not discharged to 80% every now and again, it gets ”sluggish”If it is not fully chargedIf it works at a high temperatureIf it is topped up with acid
Chargers - general
ImportantIncorrect and careless charging shortens the life of a battery
W charge characteristic IUI charge characteristic
Examples of constant current charge profiles
2100 HFP high-frequency for open tubular plate batteries - IWa charging profile
2100 HFP high-frequency for closed dryfit turbular plate batteries - IUIU charging profile
Charging process - general
Equalising chargeThe cells are adjusted
Maintenance chargeSelf-discharge is counteracted
ImportantAlways remember to switch the charger off or press the pause button each time the battery is disconnected from or connected to the charger.This avoids sparking.
Main ”Bulk” chargeThe battery is filled up
Gas phaseThe acid is agitated
Oxyhydrogen gas - oxygen and hydrogen
A battery emits gases during chargingHydrogen, in particular, is very explosive. So be careful with cigarettes, sparks and open flames near the battery
ImportantYour eyes are most at risk, so you should always use protective goggles. There mustbe an eyewash bottle near the charger.
Topping up with water
Automatically
With a filling gunManually
Without afilling gun
Aqua-jetsystem
BFSsystem
Autofillsystem
Water quality
ImportantOnly top up with demineralised wather
Normal tap water is usually around 250 microSiemens (mS).Battery water should not exceed 10 mS and never exceed 20 mS.Only use equipment in which the battery water cannot come into contact with metal, othetwise it will immediately be ionised.
Maintenance
Morning - When you start work Evening - When you stop work
Check that thecharging processhas finished
Switch off thecharger or pressthe pause button
Disconnect thebattery connectorand the chargerconnector. Do notpull the cables
Connect the batteryto the truck anddrive off.
Drive the truck close enough to the chargerThat the battery connector and the chargerconnector can easily reach each other
Turn the ignition key and switch off the current
Open the battery cover so that the gases canescape during charging
Connect the charger connector to the batteryconnector
Switch the charger on if it has a switch
Check that the charger starts before leaving it.The red light must be on. Some chargers havea yellow light
Daily
MaintenanceWeekly
FridayCheck that the acid level covers the plates. If neceessary, top it up until the platesare covered ... No more than this
NB!If the acid level is too high when the battery is charged, the cells will boil over
Check cell connections, cable terminals and connectors. Any defects must beremedied immediately.
Ensure that the cell plugs are closed. Then wash the battery with a brush andwater and wipe it dry. Use protective goggles.
Every 14 daysCheck the acid level after charging has finished and top up, if necessary, up to1-2 cm above the plates.
Maintenance
Take the temperature of the battery.It must not exceed 500c.
Monthly
If the temperature in the battery is not 300C,the density and the voltage have chhanged,as shown in the table to the right.
Measure the density or the voltage. If thevariation between cells is too great, the batterymust undergo an equalising charge.
Note:The voltage value must alwayes be0,84 higher than the density value