 BD Batteries Deep Cell Industrial
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Deep cycle Batteries
Crown Deep Cycle Batteries- Crown Battery charging
- Flooded Battery Maintenance
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Battery Maintenance
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Battery Chargers
Battery ChargersCrown Industrial Chargers
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Battery Wires, Connections, and Lugs
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Battery Safety & Disposal
Battery Disposal and RecyclingGeneral Battery Safety
Battery Connections & Charging Best Practices
Battery Lifting Best Practices
Terms, Policies & Conditions
Accounts / Credit / Etc.No Ni-Cad Batteries
Crown Flooded Battery Charging Reccomendations
Types of Charging
There are number of different charging methods; although only four need explanation. These are a Freshening Charge, Cycle Charging, Equalizing Charging and a new charging concept, called Opportunity Rapid Charging. Cycle Charge Cycle charging is the complete recharging of a battery after it has been fully or partially discharged during normal operations. Typically, a cycle charge is based on an 8-hour time period that recharges the battery and restores it to a fully charged condition. Equalizing Charge Each cell in a battery is an individual; each has a slight difference in uniformity in construction and content. The slight differences cause some cells to take less charge then the other cells in the battery. Over a period of time, the state of charge of some cells will require more charge then the other cells. To correct this condition, an equalize charge is given as it extends the charge cycle beyond the normal 8 hour charge period. This is typically for an additional 3 hours, at a very low rate. This allows the weaker cells that drift back in capacity and will limit the battery from delivering its full capacity potential. To bring all the cells back to an equal state of charge, the battery must be given an equalizing charge. An equalizing charge should be given at the end of each workweek. This will allow the battery to become fully charged and provide ample cool down time before the beginning of the next week. Freshening Charge A freshening charge is used to bring a new battery to a fully charged condition before it is placed into service, or when a battery has been standing idle for a short time period. A freshening charge is typically a soft charge at a low output (3 to 6 amperes per 100 ampere hours of the battery's rated capacity) for approximately 3 hours. This allows the battery to be restored to a fully charged condition maximizing the battery's electrical storage capability. All new batteries should receive a freshening charge before placing the battery into service. The Charging Process When a battery is placed on charge, the oppositeaction of battery discharge takes place; that is, the sulfate inthe active material of the plates in driven back into the electrolyte.This reduces the sulfate in the plates and increases the specific gravity of the electrolyte, an electrochemical process which continuesuntil the on-charge cell voltages reach 2.50 to 2.70 volts percell, dependent upon the type of charging equipment used. Finish rate or “normal” rate is thatcurrent which can be used safely any time charging is required, and which can be continued after the completion of the charge withoutcausing excessive gassing or high temperature resulting from overcharge. The finish rate is shown on the nameplate of Crown Batteries. Generally speaking, it is 3.5 amperes per 100 hours of the battery’s 6-hour rate capacity. A partially, or completely discharged battery can safely handle currents much higher thanthe finish rate, but as it approaches full charge, whatever charging rate is used must be reduced to the finish rate. The chart “Typical Recharging Characteristics” shows this finish charging rate. The curves are typical of the recharge of an 18-cell battery, whichwas discharged 100 ampere hours, and shows specific gravity, current, voltage and cell temperature. Note that after approximately 5 hoursof charge, when the battery if about 85% of its nominal full charge, the charging current is reduced sharply to a level which is maintained until charging is complete. Then the battery is fully charged, the current is stopped or should be reduced to a very low rate. Determining if a Battery is Properly Charged If the battery charging equipment is functioning properly, and if the battery is in a healthy condition, there is little chance for an improperly charged battery. If some doubt about its operation exists, the following checks are a quick way of determining a proper, fully charged battery. 1. Charging current readings will level off to thefinishing rate. 2. Charging voltage stabilizes. 3. No rise in specific gravity. 4. Normal gassing. Overcharging An excessive amount of charge results in high battery temperature, reducing the battery’s service life. Overheating To obtain maximum service life from a battery, it should be charged and operated at temperatures below 115 degrees F. Above this temperature, overheating occurs. Overheating can damage the battery and shorten its normal expected service life. The extent of the damage and service life loss depends on how high the temperature, how often the overheating occurs, and how long the batteries are subjected to high temperatures. A healthy battery charged on a properly functioning charger will have a 10 to 20 degree F. rise in temperature whenfully charged from a completely discharged state. What causes abattery to go beyond this range and overheat? The temperature rise is affected by several variable factors: 1. Age and condition of the battery 2. Battery temperature compared to ambient temperature 3. Start, intermediate and finish rate of the charger 4. The amount of overcharge given the battery In lift truck operations, a battery can overheat because of the operating requirements of the truck, as well as the operating environment. If a lift truck requires almost continuous current draws that are higher than normal, the temperature will rise. Ideally, for this operation, a “cool” battery whose temperature is 90 degrees F. or lower should be installed in the truck. However, if the lift truck operations starts withan overheated battery whose temperature is above 115 degrees F.,the continuous high current draws will tend to make the temperature rise even higher and battery damage is likely. Typical working environment where batteries must operate in an overheated condition are in a foundry, where ambient temperatures reach 120 degrees F. and higher; and in heavy-duty operations where they must be charged every 5 to 6 hours with n otime for cooling before charge. The latter problem can often be alleviated by having more than two batteries per truck. For the former, an inexpensive way to cool the battery is by directing a fan over its intercell connectors and since the conduct 60% of the heat out of the battery, the battery will cool rapidly. Charge with battery covers open. Operating and charging batteries at elevatedtemperatures is a frequent cause of battery damage and reduced service life. An experienced lift truck battery man, given the levels of operation and charging temperatures, and time span for which they are held, can estimate the percentage of service life lost. The estimated loss expressed as a percent, can serve as the basis for deciding whether to invest in extra batteries, higher capacity batteries or battery cooling equipment. Keyed Connectors Sometimes, batteries of several different voltages and ampere-hour capacities are charged at the same time at the same centralized location. Precautions must be taken to make sure that batteries are charged on chargers with mating voltages and ampere-hour ratings. Rather than rely on the persons placing the batteries on the chargers, we recommend the use of plugs and connectors of different types or the use of keyed and color-coded connectors. Gassing When a battery is charging, the electrolytic break down of the water in the electrolyte produces oxygen on the positive plates and hydrogen on the negative plates. This is normal. However,if a high charging rate is continued after the battery has been brought to its gassing voltage, the gassing becomes excessive,and abnormally larger amounts of hydrogen and oxygen gases are produced. The best indication of excessive gassing is a very noticeable “bubbling” action of the electrolyte and high electrolyte temperature. Hydrogen is a highly combustible gas and will explode on ignition when is connection in air reaches any level between 4 percent and 74 percent. (Below 4% the concentration is too weak; above 74% there is not enough oxygen left in the air to support combustion.) If you have reason to suspect excessive gassing, troubleshoot the battery and charging equipment. An unusually high usage of water indicates that excessive gassing is occurring. Undercharging Undercharging a battery, even to a small degree, if continued, leads to excessive “sulfation”. The same is true of batteries which have been left standing in an undercharged state for an extended period. High temperatures rapidly accelerate sulfation when batteries are left standing in a partially charged condition. The cells of a sulfated battery will give low specific gravity and open circuit voltage readings. On charge, voltage readings will be unusually high. The battery will not become fully charged after a single normal charging when sulfation has taken place over a prolonged period. Opportunity Rapid Charge New charger technology has been developed to allow batteries to be charged faster and at substantially higher charge rates, called Opportunity Rapid Charging or Fast Charging. Opportunity charging is charging the battery at every opportune time possible. The battery should be charged at breaks, lunches, and at the end of each shift and any other times when the battery can be charged for at least 10 minutes. Rapid charging is defined as charging the battery from 20% to 80% state of charge in two hours or less. By opportunity charging the battery the state of charge is maintained between 30% and 80% during the normal work shift. Once a day, the battery is allowed to recharge to 100% of its rated capacity. On weekends, the battery will be automatically equalize charged while it is still connected to the charger. Opportunity Rapid Charging can only be safely accomplished with a specially designed charger with sophisticated control capable of monitoring battery conditions. |
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