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 Powered by: Sun Microsystems | 
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  Battery
  Products 
 
 
 
 
 Example: Forklift Battery Watering System 
   Automatic Watering System  
  |        Filler is Easily
  Accessible        |          5gal.
  Reservoir         |   Water Level Indicator 
 
 
 
 
 The five most common
  reasons for Premature Battery Failure: Low water levels· From our experience, this is the number one cause of battery failure. ·         
  Charging batteries that are as
  little as 1” low on water can cause damage to the entire battery that can
  never be repaired. It dries and burns the uppermost portion
  of the “plates”, causing high resistance that is permanent, and
  effectively isolates the portion that remained submerged.  ·         
  Even when the proper water levels are restored, the damaged
  portion continues to cause high resistance and the battery runs much hotter
  from that point forward, causing accelerated water loss and further plate damage due to overheating.  Over Charging and
  Opportunity Charging·         
  Industrial batteries are typically
  designed to last at least 1,500 charge cycles, over
  a five to fifteen year period. Each time you charge a battery, regardless of
  how long, it constitutes one cycle.  ·         
  Consistently charging a battery
  twice per day, during lunch breaks for example, is known as Opportunity
  Charging, and reduces the useful life of a battery by 50%. ·         
  The additional heat generated by opportunity
  charging a battery usually reduces the run time equal or greater in
  proportion to the amount of charge it actually received, making the practice
  completely ineffective and costly.  ·         
  Routinely charging the battery
  before it is 80% discharged is another common form of over
  charging. For example, if you only use the battery a few hours a day, it’s
  best to use it until it is truly in need of charging before actually plugging
  it in. Remember, each charge constitutes one cycle, so try not to charge
  unnecessarily.  Over watering·         
  Commonly occurs as a reaction to low
  water levels, but is a major problem unto
  itself.  ·         
  Flushes the electrolyte from the cells and gradually dilutes the acid to the point that the battery can no
  longer function properly. In many cases this can be remedied sending the
  battery out to have the acid adjusted, but the battery’s life will still be
  shortened somewhat.  ·         
  Causes tray corrosion (listed
  below). Failing to Equalize Charge·         
  Batteries should receive an Equalize
  Charge once every 10 cycles. ·         
  Almost all chargers are equipped
  with an Equalize feature. On older chargers, this setting is usually referred
  to as Weekend or Weekly charge.  ·         
  Selecting this setting adds 3
  additional hours to a normal charge, ensuring all of the cells in the battery reach full charge, and
  the allowing extra time for the electrolyte to mix during the Gassing
  Stage.   ·         
  Failure to equalize causes reduced
  battery run time and eventual failure, due to Sulfation, Stratification, and
  an imbalanced capacity between the cells. Battery Corrosion·         
  Batteries should be rinsed or washed
  at least once per year to prevent corrosion.  ·         
  Even when the proper water levels are consistently
  maintained, sulfuric acid vapors escape during charge.
  These vapors leave an oily sulfuric acid residue on the top of the
  battery around the vent caps. Over time, the water in the residue evaporates
  leaving full strength, concentrated acid that is much more concentrated than
  the diluted acid inside the battery.  ·         
  The concentrated acid is very
  conductive. As it gradually accumulates and spreads out, it eventually makes contact
  between the intercell connectors across the top of the battery. This results
  in shorting between the cells, causing the battery to self-discharge, and additional heat during charge
  and use.  ·         
  Even though battery trays have a
  baked on powder coat finish, they will easily corrode if the residue is not
  rinsed off. The corrosion will become progressively worse until it is either
  removed, or it destroys the battery. | |||||||||||||||||||||||||||||||||||||||||||
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 CABLE CORROSION
  – REPAIRABLE:
  This is a commonly overlooked problem which causes reduced
  run time and all of the classic symptoms of a bad battery or cell. Many times this is the only problem,
  and replacing the corroded cable increases run time dramatically.  ·         
  CAUSE:
  If the battery is not rinsed periodically, acid penetrates the seal between the cable
  head and the insulation and begins to oxidize and corrode the copper
  conductors. The cable gradually swells over time as the copper breaks down,
  deteriorating the connection gradually until the battery no longer accepts a
  charge.  Examples of Battery Cable Corrosion: Swollen near
  terminal, copper is replaced by blue corrosion. 
 Positive Plate Growth
  – NOT REPAIRABLE:
  The true sign that a battery has reached the end of its
  useful life, and is in need of replacement. Typically begins to occur after 5
  years. As batteries age, the positive plates begin to soften and expand in size.
  This causes internal pressure inside the battery cells. Most manufacturers now use floating
  bushings on the positive cell posts to allow for this gradual
  expansion and reduce stress on the cells internal components. Eventually, as
  the battery reaches the end of it’s normal useful
  life, the internal pressure is great enough to push the positive posts well
  beyond normal tolerances and can begin to distort the cell covers and vent wells. Positive plate growth is normal and should be
  considered as a wear indicator. If your battery is no longer holding a charge
  and shows signs of plate growth, it should be replaced, not
  repaired. ·         
  Batteries can fail and be beyond
  economical repair without showing noticeable signs of plate growth. However, plate growth is a sure, visible sign that
  the battery is beyond economical repair. ·         
  Positive plate growth typically occurs after 5 years
  or 1,500 cycles. If it occurs in less than 5 years, it is most likely due to
  opportunity charging or over charging, which should be addressed when
  replacing the battery.  ·         
  This condition usually affects the Positive posts only, and
  will give an uneven, slanted appearance when viewed from the side, looking
  across the top of the battery. Examples of Positive Plate Growth: 
 
 ·        
  SHORT
  RUN TIME: Progressively shorter run times could be
  caused by a malfunctioning battery OR charger. It is best to have both
  checked if you begin to experience shortened run time or suspect a problem. ·        
  EQUALIZE
  CHARGE: Industrial batteries must receive an
  equalize charge at least once per month, or permanent damage will result.
  Never equalize more than once every 5th charge cycle, or damage will result. Reason:
  Selecting equalize mode on your charger adds 3 additional hours of charge
  time to that charge cycle, ensuring all of the cells reach 100% charge. Equalizing too
  often or too little will shorten battery life.   ·        
  WHEN TO
  ADD WATER, AND HOW MUCH TO ADD: Water can be
  added before or after charging. Add just enough water to cover the perforated
  element protector (visible at the bottom of the vent well).  ·        
   ·        
  WHAT
  KIND OF WATER TO USE: In general, normal city water will
  suffice, but if you have any doubts about purity of the local water supply,
  A) contact the GB battery supplier in your area B) get a chemical analysis of
  the water C) use distilled water. ·        
   ·        
  SPECIFIC GRAVITY (SPGR): See SPGR chart
  below. ·        
  OVER DISCHARGING: Never over
  discharge batteries. More is not necessarily
  better when it comes to recharging batteries. Most battery manufacturers
  warrant their batteries for up to 1,500 cycles of charge and discharge provided, among other things, that
  the battery is never discharged beyond 80%. This normally
  coincides with an eight-hour shift. Trucks fitted with extra equipment such
  as clamps, high speed lifts, etc. will need a higher capacity battery to ensure the battery is
  not discharged beyond 80%. Lift truck
  interrupts are available to detect the correct discharge level and are recommended by battery
  manufacturers as a means of ensuring batteries are not over discharged. The best way to ensure batteries
  are not being overcharged is to periodically (once a
  month) check the temperature of the center cell on a battery at the end of regular
  charge. If the temperature of the electrolyte is more than
  36° F above the ambient temperature, call your battery technician—
  there is a problem. ·        
  AVOIDING SPARKS: Batteries produce
  and store hydrogen gas, which is highly explosive. Never weld near a battery.
  Never place metal objects on batteries. Such
  objects can cause a short circuit between adjacent cells and result in possible injury to those
  close to the battery. Similarly, people charged with caring for or operating
  batteries should not wear any metal jewelry. ·        
  UNDER-SIZED CHARGERS: A charger that is
  more the 100AH less than the your battery’s rated capacity.
  Will result in an undercharged battery with significant reduction in
  operating life. Your local GB vendor has all the information to ensure the
  battery and chargers are precisely matched. ·        
  OVER-SIZED CHARGERS: A charger that is
  over 100AH more than your battery’s rated capacity.
  Can overcharge and overheat your battery, reducing the operating
  life of your battery. ·        
  WHEN TO
  REPLACE A BATTERY: Repair or replace batteries when capacity that has fallen below 80% of its
  rated capacity. Continuing to operate a bad
  battery can damage a truck's electric motor and electronics. Failing
  batteries also require recharging more frequently, wasting hundreds or thousands
  of dollars in energy per year, depending on the size of your fleet. ·        
  RECORD
  KEEPING: We recommend that each forklift, battery
  and charger in your fleet be given a unique number for easy identification
  and tracking purposes. Keep regular records on the maintenance of batteries.
  For instance, keep a log of ever time a battery is watered and equalize
  charged, or at minimum, each time an operator complains of short run time and
  whenever cells or cables are replaced. These records
  will be invaluable when it comes to predicting when battery replacement will
  be necessary. ·        
  FORMULAS:
   § Charger Model# Breakdown: Example, Model GB100-3-18-750 = GB brand, 100% rated, 3 phase, 18 cell (36 volt), 750AH (Ampere Hour). §  Battery
  Model# Breakdown: Example, Model 18-125-13 = 18 cells (x2 = 36 volt), 125AH per plate, 13 negative plates. §  Calculating
  AH Capacity: Negative plates per cell – 1,  / 2 x AH per plate = AH (Ampere Hour).  §  Example,
  18-125-13: 13 – 1 = 12, / 2 = 6 x 125 = 750AH §  Calculating
  KWH Capacity: AH x
  Volts (2v per cell) = WH (Watt Hour) / 1000 x .97
  (efficiency factor) = KWH (Kilo Watt Hour) §  Example,
  battery model 18-125-13, 36V / 750AH: 750 x 36 = 27,000 / 1000 = 27 x .97 =
  26.19KWH. ·        
  STATE OF CHARGE: Typical
  no-load voltages vs. state of charge:§  Sample
  voltages are for a 12-volt / 6 cell battery system (figured at 10.5 volts =
  fully discharged, and 77 degrees F). For a 24-volt
  battery multiply by 2, for a 36-volt battery multiply by 3, 48-volt battery
  multiply by 4. VPC is the volts per individual cell - if you measure more than a .2 volt
  difference between each cell, you need to equalize, or the battery
  is beginning to go bad, or it could be sulfated. These voltages are for
  batteries that have been at rest for 3 hours or more. Batteries that are
  being charged will be higher - the voltages while charging will not tell you
  anything, you have to let the battery sit for approx. 3hrs. For longest life,
  batteries should stay in the green zone. Occasional dips into the
  yellow are not harmful, but continual discharges (or “cycles”) to those levels will shorten
  battery life considerably. It is important to realize that voltage
  measurements are only approximate. Note the large voltage drop in the
  last 10%. 
 
 Other Battery Questions and AnswersHow are batteries rated and what
  do the ratings mean in battery selection?  How does the Cold Cranking Amperage rating help me select
  a battery?  What does the Reserve Capacity rating mean and how does
  it apply to deep cycle batteries?  What is
  the difference between deep cycle batteries and starting batteries?  Does overcharging damage batteries?  Does over discharging damage batteries?  How can I evaluate the health and state of charge (SOC)
  of a battery?  
 1) BATTERY
  RATINGS 
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