In an electric stacker, the operation of all systems depends on the power supply. To maintain the normal operation of all systems, we must rely on an efficient power source, which is provided by an efficient [battery] Therefore, batteries are as important to electric stackers as gasoline is to cars
The battery is so important to the electric stacker, so we must pay more attention to the care of the battery, because the price of the battery is very expensive. Once there is a problem, the whole stacker cannot be used. Therefore, the stacker operator needs to pay special attention to the basic maintenance of the battery
The general operators often know a little about the battery maintenance, so that the battery is less noticed by users. Therefore, this operation specification provides operators with some basic battery maintenance methods and special precautions during charging and use, hoping to provide users with a better understanding of the battery, keep the battery in the best condition and provide high-efficiency operation of the stacker
I Battery principle:
Lead-acid batteries use chemical changes to store electric energy, and when they need to be used, they release electric energy into chemical changes
Each sub cell is immersed in electrolyte (dilute sulfuric acid) by anode (PbO2) and cathode (PB). Due to chemical action, a voltage of about 2 volts is generated between the two poles The basic working principle is as follows:
Anode electrolyte cathode discharge anode electrolyte cathode
PbO2 + 2H2SO4 + Pb PbSO4 + 2H2O +PbSO4
Lead dioxide dilute sulfuric acid sponge lead charging lead sulfate water lead sulfate
II Battery construction:
III Battery action characteristics:
1. Capacity of storage battery: the battery for electric stacker is a covered battery, and its capacity is expressed by the following conditions:
Specific gravity of electrolyte.............................. 1.28/20 ℃
Discharge current................................. 5-hour rate current
Discharge termination voltage................................. 1.70v/cell
Electrolyte temperature in discharge..................... 30 ± 2 ℃
2. Battery management
a. Voltage drop during discharge
The reason why the terminal voltage in discharge is lower than that before discharge is as follows:
? v = e - I * r v: terminal voltage
. e: voltage before discharge
1: Discharge current
. R: internal impedance
·When discharging, the specific gravity of electrolyte decreases and the open circuit voltage also decreases
The internal impedance increases during discharge, which is about 2 ~ 3 times higher than that of complete discharge Therefore, the battery voltage when lifting the fork is lower than that during walking, because the horsepower of the lifting oil pressure motor is higher than that of the walking motor, so the discharge current is larger when lifting
b. Discharge rate and capacity of battery
When the discharge current is large, the internal voltage drop increases, resulting in a sharp drop in the terminal voltage, which limits the capacity to discharge The reason is that the slow diffusion of electrolyte in the discharge slows the supply of sulfuric acid to the electrode plate. Therefore, the actual service time will be reduced when the lifting operation is frequent or the high-speed running
c. Capacity representation of storage battery
If the discharge termination voltage is low, increase the discharge capacity. During the capacity test, set the following standards according to the discharge rate:
5HR………………1.7 V/cell
3贬搁………………1.65痴/肠别濒濒
1贬搁………………1.55痴/肠别濒濒&苍产蝉辫;
Discharge below the above voltage will not increase the discharge capacity. In case of excessive discharge, the active substance will deteriorate, which will have a bad impact on the service life of the battery Therefore, raise the fork when there is no load if the battery voltage is 1.75v/cell (42V when 24 are connected in series)
It is absolutely forbidden to continue to use, and the charging operation must be carried out immediately
d. Battery temperature and capacity
If the battery temperature is low, its capacity is significantly reduced for the following reasons
The diffusion of electrolyte is poor, and the chemical reaction of the acting substance between the two electrodes becomes slow
·When the impedance of electrolyte increases, the open circuit voltage also decreases
The 5-hour rate capacity of coated battery for electric stacker varies with battery temperature Therefore, the actual use time in winter is shorter than that in summer· The lifting operation in the refrigerator is used for a long time (high current discharge operation), and the actual use time per day is shortened
To prolong the actual use time, it is better to raise the battery temperature in winter or before using in the cold storage, but it is more appropriate to consider that the battery temperature is about 30 ℃
e. Relationship between discharge depth and specific gravity:
The specific gravity of the electrolyte of the battery is directly proportional to the discharge capacity. Therefore, if the specific gravity of the battery when fully charged and 100% discharged is known, the discharge capacity of the battery can be calculated The specific gravity measurement method shows that the discharge depth is the most accurate. Therefore, please measure and check the specific gravity regularly after use to avoid excessive discharge of the battery
During the specific gravity measurement, the temperature of electrolyte can be measured at the same time. When converted into the specific gravity at 20 ℃, its value can not be less than 80%, and the discharge value is about 1.16
f. Discharge state and internal impedance:
The internal impedance increases gradually with the progress of discharge and reaches the maximum at the end of discharge This is because when the discharge is in progress, the electrode plate produces lead sulfate of poor electrical conductor, and the specific gravity of electrolyte decreases and the impedance increases
Charge the battery as soon as possible after discharge, otherwise white lead sulfate will appear on the electrode plate, which will seriously affect the service life of the battery The so-called white lead sulfate is the plate
After discharge, it turns into lead sulfate. If it is placed without charging, it will turn into white lead sulfate. Even if it is recharged, it is difficult to recover
g. Temperature at discharge:
During rapid discharge, the internal impedance also increases rapidly, and the temperature of the battery also increases with it. The temperature at the end of discharge increases. Similarly, the temperature at the end of charging also increases. It is hoped that the end temperature can be reduced to below 40 ℃
h. Charging characteristics of battery:
When the voltage of each single battery reaches 2.35v ~ 2.4V, the gas occurs and the voltage begins to rise rapidly. The gas reaches the maximum in the middle of recharging and the charging voltage remains almost constant
The current in the middle of charging is almost spent on decomposing water into gas to increase the temperature. Therefore, the medium-term charging current should not be too large, otherwise the battery temperature will rise excessively and affect the service life
i. Gas generation and ventilation:
The gas generated during charging is a mixture of hydrogen and oxygen. Oxygen is a highly explosive gas. If the hydrogen concentration in the air exceeds 3.8%, it will explode in case of fire and gas. Therefore, the charging place needs to be well ventilated, and fire and gas cannot be close to the location of the battery
j. Determination of specific gravity of electrolyte:
The specific gravity is measured by a hydrometer. The outer cylinder is filled with inhaled electrolyte. Read the scale above the electrolyte of the hydrometer in the cylinder. The specific gravity of the battery will change with the temperature. If the temperature changes by 1 ℃, the change of specific gravity will be 0.0007. Therefore, when measuring the specific gravity, the temperature must be measured at the same time, and then converted to the specific gravity at the standard temperature of 20 ℃ by the following formula
S20: specific gravity after conversion at 20 ℃
S20 = st + 0.0007 * (t – 20) st: measure the specific gravity at t ℃
T: measured temperature of electrolyte
k. Supplement of distilled water:
After the cycle of charge and discharge process, the electrolytic liquid level will slowly decrease. Therefore, it is necessary to regularly check and supplement distilled water to the specified liquid level If you forget to replenish distilled water and expose the plate to the liquid level, the plate will be damaged and special attention must be paid
If the added distilled water exceeds the specified liquid level, it may overflow the battery surface during charging, causing the burning of the electrolytic cell and the corrosion of the electrode, so great attention must be paid
3. Maintenance:
Key points for daily use:
Please pay special attention to the following precautions
? avoid excessive discharge
·Charge moderately and do not overcharge
Keep electrolyte at proper level
? Explosive gas will be generated during charging, so fire and gas cannot be approached
? do not make the battery temperature exceed 50 ℃ at any time
? keep the battery connector and its surrounding environment clean and dry
? The battery needs to be charged and discharged every day, and the deeper the discharge depth, the shorter the service life If the daily usage is small and it takes several days to recharge, the battery in place will deteriorate, so the battery life can not be judged only by its charge and discharge times
★ the battery shall not be stored for more than 30 days to avoid deterioration and failure ★
IV Battery condition measurement:
a. Daily usage:
? select the pilot cell
Select the single battery in or near the central battery pack
? Base battery ‰ (it is recommended to choose the fourth one from the negative pole) and mark it, so as to infer the condition of other batteries from the liquid level, specific gravity and temperature of the battery
·Inspection before operation
? check the electrolytic liquid level of "reference battery"
If the electrolyte of the "reference battery" is insufficient, distilled water must be added to all batteries. When adding distilled water, pay attention to the condition of the pontoon and do not replenish it excessively
? check the voltage
If the fork is raised under no-load condition and the voltage is maintained at 42V or above, it can be operated
Check the power plug
Only when the power plug is properly plugged in can the stacker be operated
Key points for attention in use
? avoid driving the stacker while raising the fork
? driving at low speed and high stacking function make the battery have a long service life
Avoid vibration and impact
? when the rising speed and walking speed of the fork feel reduced, stop using the stacker and carry out charging operation. When the walking performance is reduced, it is in the state of excessive discharge
? charge when the stacker is idle, which can increase the efficiency of the battery
? Inspection and treatment after use
After the stacker is in operation, please carry out the following inspection and treatment:
Cleaning and finishing
Due to the weather and operating environment, the battery may be stained with rain or dust, so clean it with a rag
Charging
Charge the battery according to the actual needs. Before charging, check whether the charger connector and electric connector are properly connected
b. Regular maintenance and inspection:
? weekly inspection
Check once a week and register
? measure the voltage, specific gravity and liquid temperature of the "reference battery" before and after use
? during charging, open the cover first and check whether the position of the indication mark on the top of the pontoon is appropriate (the correct water level is 12mm above the top of the grid)
If the water level is too high, the electrolyte will overflow during charging, resulting in weak acidity of the electrolyte If the water level is not enough, the top plate will be exposed, which will reduce the service life of the battery. When adding water, non-metallic containers must be used, and only approved distilled water can be added to meet the required standard of purity
H never use acid water as make-up water H
ⅸ when adding distilled water, avoid injecting too much or too little distilled water into the battery
? check all connections and tidy up worn lines or damaged insulators
? check the condition of each pole and whether the connecting wires are firm, and whether the battery end cover is installed and fixed correctly
? it is necessary to keep the top of the battery clean and dry, because any dirt and moisture will become the conductor of electricity,
V Cause of battery damage:
The service life of electric stacker battery is generally about 1200 ~ 1500 times of charge and discharge. Calculated by 300 working days a year, it should have a service life of 4 ~ 5 years. However, the user's maintenance of the battery is related to the increase or decrease of the battery life. The user should pay special attention to the following factors that may cause battery damage, which should prolong the service life of the battery
There are several general reasons for battery damage:
1. Water shortage:
Generally, hydrogen and oxygen are released due to chemical action during battery charging, so the water in the battery will be reduced, so it is necessary to supplement water If the water in the battery is reduced without replenishment, the electrode plate in the battery will be exposed to the air and burned out during charging If too much water is added, the electrolyte in the battery will overflow during charging, reduce the concentration of dilute sulfuric acid in the battery, and indirectly corrode the battery iron box, resulting in leakage
2. Excessive discharge:
Generally, when the battery is used, the electricity meter will decrease step by step according to the capacity of the battery itself. If the indication of the electricity meter changes to red light flashing, the battery discharge has reached about 80% and needs to be charged immediately. If the battery discharge exceeds 80%, the lead sulfide outside the battery will be damaged due to high heat. If the lead plate expands and causes short circuit, the battery will not be able to store electricity
3. Overcharge:
Overcharge will greatly reduce the water content of the battery and make the electrolyte too thick, just like the reason for the lack of water in the battery. Therefore, the most likely reason for overcharge of the battery is that the charger cannot automatically power off, so it is necessary to send the charger for repair
4. Impurities in electrolyte:
When replenishing water, use battery water instead of distilled water, resulting in high specific gravity in electrolyte Generally, the battery water is composed of dilute sulfuric acid. Therefore, if the battery water is added to the battery, the electrode plate of the battery will be burned and the battery will be damaged by self short circuit Therefore, if non distilled water is used when adding water, bad self discharge will occur in the battery due to other impurities in the water quality, resulting in battery damage
Therefore, users of the electric stacker should know the condition of the battery at any time. They should check the condition of the battery before operation every day to reduce the above causes of battery damage. If there are any problems, they can contact the agent manufacturer of the electric stacker at any time to ensure the normal operation of the electric stacker
Vi Battery charging
1. Environment of charging and use place
? conditions of charging place
? avoid rain and direct sunlight
? there is good ventilation and no fire and gas, and there is no possibility of fire and gas near the site
Vibration and dust should be rare
The space for inspection and maintenance shall be sufficient
? non combustible materials should be used for building materials, with good acid resistance and drainage
·Conditions of the place of use
? the road should be flat and the inclination should be small
? avoid places with fire (including sparks of grinding machine)
Don't get wet
? avoid direct sunlight and use in high temperature rooms
2. Charger
1. Specifications and standards of external power supply of charger
The standard specifications of external power supply of general charger are as follows:
24V AC220V / 40A / 60Hz single-phase or three-phase
48V AC220V / 80A / 60Hz three-phase
80V AC220V / 100A / 60Hz three-phase
2. Battery charging
When the power indicator on the instrument panel is red, it indicates that the battery is low and must be charged immediately The charger shall confirm several key points when delivering the vehicle:
1. Whether the AC power of the external power supply of the charger is consistent with the specification of the charger. Generally, the AC power supply is three-phase 220V. If not, the customer must be asked to improve
2. Charging operation steps are as follows:
a. Open the battery box cover and support it in a fixed position with a support rod
b. Open the battery cover of each battery, check whether the water level of the battery is in the normal position, and make the gas generated during charging escape
c. Connect the power connector of the battery and the power connector of the charger
d. Generally, there are two kinds of chargers: automatic charging and equal charging, which can be operated by selecting the switch, and the charger itself is a fully automatic opening and closing mode. When the battery is connected with the charger, the charging opportunity will start automatically and set the automatic charging mode by itself. When the charging starts, the indicator light of the charging switch will be on When charging is completed, the charger will automatically stop charging
e. When the abnormal wiring and charging lights on the charger panel are on, please immediately notify the Department of the company for maintenance
f. ★ do not unplug the power plug during charging
△ it is absolutely forbidden to open the power connector between the charger and the battery immediately during charging, because sudden opening will cause excessive reverse charging current to rush in
The charger is damaged due to being inside the charger And will produce sparks, ignite the hydrogen in the charging process and produce an explosion If it is necessary to unplug, it shall be carried out in the following order
? press the stop button First turn off the power switch of the charger and stop charging
·Turn off the AC power Pull down the AC power switch of the charger and then pull it off
Power connector between charger and battery
Then unplug the power plug
3. Matching of charger
a. If the charging current of the charger is too small, it will cause insufficient charging
b. Excessive charging current of charger will cause over charge
4. Special precautions during charging
c. When charging, smoking and any possibility of fire and gas generation are prohibited within 10 meters around. Because hydrogen will be generated during charging, it is best to have ventilation equipment
d. The charging environment needs circulation to avoid dust and water
e. The charger should be set high to avoid short circuit caused by the influence of ground moisture
f. It is suggested that if the customer does not use the charger, the charger should be covered to prevent dust from entering the charger, and the covered carton should be removed when charging
5. Timing of charger
a. Generally, the charging time is about 6 ~ 8 hours, so charging at off duty will not affect the factory operation
b. If the lifting speed of lifting is reduced or intermittent or interrupted, the battery is lower than 20% and needs to be charged immediately
c. If the customer uses a large amount of battery every day, it should be charged every day, and it is best to charge the battery after using it to 30 ~ 40%
d. If the customer uses less, it needs to be charged at least 2 ~ 3 times a week
e. If the customer has three shifts, he should advise the customer to buy another set of batteries
6. Charging method of charger
a. Normal charging:
The charging time varies according to the battery capacity and discharge time Discharge 75%~100% and charge continuously for 8~13 hours
b. Equal charging: (equal charging)
When the battery is used for a period of time, the terminal voltage of the connected 24 sub batteries will be unbalanced. At this time, it can be balanced by equal charging
Implement when the battery has the following abnormal conditions:
? 100% over discharge. When the battery is not used for a long time or has been over discharged (the specific gravity of electrolyte is less than 1.10), it must be charged equally
·Battery make-up distilled water
The specific gravity and liquid temperature of all battery electrolyte are measured and converted to the specific gravity at 20 ℃, and the relative difference is more than 0.02
?. Equal charging is usually carried out once a month. If the discharge is repeated every day, it must be carried out once a week. The average power distribution inside the battery has been extended
?. It is not allowed to switch the automatic / equal charging switch while recharging is in progress
P danger warning: the hydrogen produced during charging is explosive, so it is strictly prohibited to smoke or fire in the charging area It's best to make a shelf for the charger and raise it to avoid damage to the charger due to moisture on the ground
c. Supplementary electricity:
After the operation, it will be implemented when the power is insufficient
