Preface
In an electric stacker, the operation of all systems depends on the supply of electricity, and to maintain the normal operation of all systems, you must rely on a highly efficient power source, which is provided by high-efficiency [battery] Therefore, batteries are as important to electric stackers as gasoline is to automobiles.
The battery is so important for the electric stacker, and the care of the battery must be paid attention to because the battery is very expensive.If there is a problem, the entire stacker cannot be used, so the operator of the stacker is basically Special care and attention are required for maintenance.
And the general operator often knows a little about the maintenance of the battery, which makes the battery less noticed by the user, so this operating specification provides the operator with some basic battery maintenance methods and special precautions when charging and using, hoping to provide users with a better understanding Battery, so that the battery can be kept in the best condition, providing high efficiency operation of the stacker.
1. Battery principle:
Lead storage batteries use chemical changes to store electrical energy, and when used, they release electrical energy into changes in chemical substances.
Each sub-cell consists of anode (PbO2) and cathode (Pb) immersed in electrolyte (dilute sulfuric acid). 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, spongy lead, charging, lead sulfate, water, lead sulfate
2. Battery structure:
Three. The characteristics of the battery:
1. The capacity of the storage battery: the battery used in the electric stacker is a wrapped battery, and its capacity is expressed by the following conditions:
Specific gravity of electrolyte…………………….1.28/20℃
Discharge current................................. 5 hour rate current
Discharge end voltage……………………1.70V/cell
Electrolyte temperature during discharge………………30±2℃
2. Battery management
a. Voltage drop during discharge
The reason why the terminal voltage during discharge is lower than the voltage before discharge is as follows:
? V=E-I*R V: terminal voltage
.E: Voltage before discharge
I: Discharge current
.R: internal impedance
The specific gravity of the electrolyte decreases during discharge, and the open circuit voltage also decreases. The internal impedance increases during discharge. The discharge (100%) is approximately 2 to 3 times higher than the full discharge. Therefore, the battery voltage when the fork is raised is lower than the voltage during walking. , Because the horsepower of the lifting hydraulic motor is greater than the horsepower of the walking motor, so the discharge current when lifting is larger
b. Battery discharge rate and capacity
If the discharge current is large, the internal voltage drop increases, resulting in a sharp drop in the terminal voltage. Because the terminal voltage drops, the capacity that can be discharged is limited. The reason is that the diffusion of the electrolyte during discharge is slow and the sulfuric acid component of the electrode plate is recharged. Slow, so when the lifting operation is frequent or high-speed walking operation, the actual use time will be reduced.
c. Capacity of battery
When the discharge termination voltage is low, the discharge capacity is increased. In the capacity test, the following standards are set according to the discharge rate:
5HR………………1.7 V/cell
&苍产蝉辫;3贬搁………………1.65痴/肠别濒濒
&苍产蝉辫;1贬搁…………1.55痴/肠别濒濒
Discharging below the above voltage can not increase the discharge amount. When over-discharging, the active material will deteriorate, which will have a bad impact on the life of the battery. Therefore, the fork will rise when there is no load. If the battery voltage is 1.75V/cell(24 42V in series) is absolutely forbidden to continue to use and must be charged immediately.
d. Battery temperature and capacity
If the battery temperature is low, its capacity is significantly reduced for the following reasons.
? The electrolyte has poor diffusion, and the chemical reaction of the acting substance between the two electrodes becomes dull.
The impedance of the electrolyte increases, and the open circuit voltage also decreases.
The 5 hour rate capacity of the covered battery for electric stacker varies with the battery temperature. Therefore, the actual use time in winter is shorter than that in summer. The actual use time is shortened. To extend the actual use time, it is best to increase the battery temperature in winter or before using it in the refrigerator, but it is more appropriate to consider the battery temperature at about 30 ℃.
e. Relationship between discharge depth and specific gravity:
The specific gravity of the battery's electrolyte is proportional to the amount of discharge, so if you know the specific gravity of the battery when it is fully charged and when it is 100% discharged, you can calculate the discharge of the battery. The specific depth measurement method knows that the depth of discharge is the most reliable, so please The specific gravity should be measured and checked regularly after use, and the battery cannot be over-discharged. During the specific gravity measurement, the electrolyte temperature can be measured at the same time. When converted to 20℃, the specific gravity should not be lower than 80% of the discharge value of about 1.16.
f. Discharge status and internal impedance:
The internal impedance gradually increases with the discharge and reaches the maximum value at the end of the discharge. This is because when the discharge is in progress, the electrode plate produces lead sulfate that is an electrically poor conductor, and the specific gravity of the electrolyte decreases to increase the impedance.
After the discharge is completed, it must be charged as soon as possible, otherwise the plate will produce white lead sulfate, which seriously affects the life of the battery. The so-called white lead sulfate (Salphation) is that the plate becomes lead sulfate after discharge, if it is not charged, it will be converted It becomes white lead sulfate, even if it is recharged, it is difficult to restore it.
g. Temperature during discharge:
During rapid discharge, the internal impedance also increases rapidly, and the temperature of the battery also rises, and the temperature at the end of the discharge rises.Similarly, the temperature at the end of the charge also rises, hoping to reduce the final temperature to below 40 ℃.
h. Charging characteristics of battery:
Charging proceeds until the voltage of each single cell reaches 2.35V~2.4V, gas occurs, and the voltage also begins to rise rapidly.The gas generation reaches the maximum in the middle of recharging, and the charging voltage remains almost constant.
Almost all the current in the mid-charging period is spent decomposing moisture into gas to increase the temperature, so the mid-term charging current should not be too large, otherwise it will cause an excessive rise in battery temperature and affect the life.
i. Gas generation and ventilation:
The gas that occurs 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 the event of fire.Therefore, the charging site needs to be well ventilated, and the fire cannot be close to the battery. s position.
j. Determination of specific gravity of electrolyte:
The specific gravity is measured with a specific gravity meter. The electrolyte is drawn in the outer cylinder. Read the scale above the electrolyte of the specific gravity meter in the cylinder. The specific gravity of the battery will change with temperature. If the temperature changes by 1℃, the specific gravity will change to 0.0007, so When measuring the specific gravity, the temperature must be measured at the same time, and then converted to the specific gravity S20 at the standard temperature of 20℃ using the following formula: The specific gravity after conversion at 20℃ S20 = St + 0.0007 * (t – 20) St: The specific gravity is measured at t℃
t: measured temperature of electrolyte
k. Supplement of distilled water:
After the cycle of charge and discharge, the electrolyte level will slowly decrease, so it is necessary to regularly check and replenish distilled water to the specified liquid level. If you forget to add distilled water and expose the electrode plate to the liquid surface, the electrode plate will be injured and must be injured. Special attention. If the added distilled water exceeds the specified liquid level, it may overflow the battery surface during charging, causing burnout of the electrolytic cell and corrosion of the pole, so great care must be taken.
3. Maintenance:
Points for attention in daily use:
Please pay special attention to the following precautions
? Avoid excessive discharge.
Charge in moderation and do not overcharge.
? Keep the electrolyte at the proper level.
?Explosive gas will be generated during charging, so fire gas should not be brought close.
?Do not allow the battery temperature to exceed 50°C at any time.
?Keep the battery connector and its surroundings clean and dry.
? The battery needs to be charged and discharged every day, and the deeper the depth of discharge, the shorter the life. If the daily use is small and it takes a few days to recharge, the battery in place will deteriorate, so the battery life cannot be limited. Calculate the number of charge and discharge to determine
★ The battery must not be left for more than 30 days to avoid deterioration and deterioration ★
Four. Battery condition measurement:
a. Daily use method:
?Select the reference cell (Pilot Cell)
Select the single battery located in or near the central part of the battery pack as the
?Base battery ‰ (It is recommended to select the fourth one from the negative electrode), make a mark, from which the liquid level, specific gravity, temperature status of the battery can be used to estimate the status of other batteries.
·Check before operation
?Check the electrolyte surface of the “reference battery”
If the electrolyte of the "base battery" is insufficient, all batteries must be added with distilled water. When adding distilled water, be careful of the condition of the float and do not over-replenish.
?Check the voltage
If the fork is raised under no-load conditions and the voltage remains at 42V or above, it can be operated.
?Check the power plug
Only when the power plug is correctly inserted can the stacker be operated.
Points for attention during use
? Avoid raising the fork while driving the stacker.
? Driving at low speed and stacking function can make the battery have a longer service life.
?Avoid vibration and shock.
? When the speed of the fork rises and the walking speed feels down, stop using the stacker for charging, and when the walking performance is reduced, it is in a state of excessive discharge.
?Charge when the stacker is idle, which can increase the efficiency of the battery.
?Inspection and handling after use
After the stacker is in operation, please implement the following inspection and treatment:
?Cleaning and finishing
Due to weather and operating environment, the battery may be covered with rain or dust, so use a rag to clean it.
? charging
According to the actual need to charge the battery, before charging, check whether the charger connector and the electric delay connector are properly connected.
b. Regular maintenance inspection:
? Weekly inspection
Check once a week, and register the following forms
?Measure the voltage, specific gravity, and liquid temperature of the “reference battery” before and after use
? During the charging process, you should first open the lid to check whether the position of the indicator mark on the top of the float is appropriate, (the correct water level is 12mm above the top of the grid)
If the water level is too high, it will cause the electrolyte to overflow during charging, causing the acidity of the electrolyte to weaken. If the water level is not enough, the top plate will be exposed, which will reduce the life of the battery. Metal containers, and can only add certified distilled water to meet the purity requirements.
H Never use acidic water as supplemental water H
?Add distilled water to avoid pouring too much or too little distilled water into the battery.
?Check all connections and sort out worn lines or damaged insulators.
?Check the condition of each pole and whether the connecting wires are firm, and whether the battery end cover head is installed and fixed correctly.
&ARIng; It is necessary to keep the top of the battery clean and dry, because any dirt and moisture will become a conductor of electricity,
V. Reasons for battery damage:
The life of the battery of the electric stacker is generally about 1200 ~ 1500 times of charge and discharge, calculated based on 300 working days a year, it should have a life of 4 ~ 5 years, but the maintenance and maintenance of the battery by the user is related to the battery life The user should pay special attention to the following factors that will cause battery damage, which should extend the life of the battery.
The general causes of battery damage are roughly the following factors:
1. Water shortage:
During the charging process of a general battery, hydrogen and oxygen are released due to the chemical action, so the moisture in the battery will be reduced, so it is necessary to replenish the moisture. If the moisture in the battery is reduced and not replenished, it will cause the inner plate of the battery to be exposed to In the air, the electrode plate will burn out during charging. If too much water is added, the electrolyte in the battery will overflow during charging, reducing the concentration of dilute sulfuric acid in the battery, indirectly corroding the battery iron box, causing leakage.
2. Overdischarge:
Generally, when the battery is in use, the fuel gauge will gradually decrease according to the capacity of the battery itself.If the indicator of the fuel gauge changes to a red light flashing, the battery discharge capacity has reached about 80% at this time, and it needs to be charged immediately.If the battery discharge capacity exceeds 80% At the time, the lead sulfide outside the battery will cause damage to the battery lead plate due to high heat.If the lead plate is expanded to cause a short circuit, the battery becomes unable to store electricity.
3. Overcharge:
Overcharging will reduce the battery's moisture a lot, and make the electrolyte too thick, just like the reason for the battery's lack of moisture, so the most likely cause of the battery's overcharging should be that the charger cannot automatically power off, so the charger needs to be repaired .
4. There are impurities in the electrolyte:
When rehydrating, instead of using distilled water, use battery water, which causes the specific gravity in the electrolyte to be too high. Because the general battery water composition is dilute sulfuric acid, so if the battery water is added to the battery, it will definitely burn the battery plate It will cause the internal battery to short-circuit and damage itself. Therefore, if non-distilled water is used when adding water, the water will contain other impurities, which will cause a bad self-discharge situation inside the battery and cause battery damage. Therefore, the electric stacker is used The person must keep abreast of the status of the battery.Check the status of the battery before operation every day to reduce the above causes of battery damage.If you have any questions, you can always contact the electric stacker agent manufacturer to ensure that the electric stacker is working properly.
6. Charging the battery
1. Environment of charging and using place
? Conditions of charging site
?Avoid rain and direct sunlight.
? is well ventilated, there is no fire, and there is no possibility of fire near the scene.
?Vibration and dust are rare
?Check and maintain enough space.
?Use non-combustible materials for building materials, with good acid resistance and drainage.
· Conditions of use
? The road surface should be flat and the slope should be small.
? Avoid fires (including sparks from grinders).
?Do not get rain.
?Avoid direct sunlight and use in high-temperature indoors.
2. Charger
1. Specifications of external power supply for charger
The standard specifications of the external power supply of the 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 a red light, it means that the battery has insufficient power and must be charged immediately. The charger must confirm several key points when delivering the car:
1. Whether the AC power of the external power supply of the charger meets the specifications of the charger, the general AC power supply is three-phase 220V, and if it does not meet the requirements, the customer needs to be improved.
2. The charging operation steps are as follows:
a. Lift the cover of the battery box 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 allow the gas generated during the charging process to escape.
c. Connect the power connector of the battery to the power connector of the charger.
d. Generally, the charger has two types: automatic charging and equal charging, which can be operated by a selection switch. The charger itself is fully automatic opening and closing. When the battery is connected to the charger, the charging machine will start automatically and set automatic charging. Mode, when charging starts, the charging switch indicator will light up. When the charging is completed, the charger will automatically stop the charging operation.
e. When the abnormal connection of the charger panel and the abnormal charging lamp are on, please notify our company department for repair immediately.
f. ★Do not unplug the power plug during charging ★,.
△ It is absolutely forbidden to disconnect the power connector between the charger and the battery immediately during the charging process, and the excessive reverse charging current caused by the sudden pulling meeting will rush into the charger and cause damage to the charger. The hydrogen gas will explode. If it must be unplugged, it should be carried out in the following order
? Press the stop button. Turn off the power switch of the charger first to stop charging.
Turn off the AC power. Pull down the AC power switch of the charger, and then disconnect the power connector of the charger and the battery.
?Remove the power plug
3. Matching of the charger
a. If the charging current of the charger is too small, it will cause insufficient charging.
b. Excessive charging current of the charger will cause over charge.
4. Special considerations when charging
c. During charging, smoking is prohibited within 10 meters and any fire may be prohibited. Since hydrogen gas is generated during charging, it is best to have a place with ventilation equipment.
d. The charging environment needs to circulate to avoid dust and water.
e. It is best to elevate the charger to avoid short circuit due to the influence of ground moisture.
f. It is recommended 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 during charging.
5. When to use the charger
a. The general charging time takes about 6~8 hours, so charging after get off work will not affect factory operations.
b. If the lifting speed of the lift is reduced or intermittent or interrupted, the battery should be charged immediately if it is less than 20%.
c. Customers use a large amount every day, they should be charged every day, and it is best to use the battery to 30~40% and then charge it best.
d. If the customer's usage is low, it needs to be charged at least 2-3 times a week.
e. If the customer has a three-shift system, the customer should be advised to purchase another set of batteries.
6. Charging method of charger
a. Ordinary charging:
It is implemented after daily use, and the charging time varies according to the battery capacity and discharge time. Discharge 75%~100% requires continuous charging for 8~13 hours.
b. Equal charge: (EQUAL CHARGING)
When the battery is used for a period of time, the terminal voltage of the 24 connected sub-cells will be unbalanced.At this time, it can be balanced by equal charging.
Implemented when the battery has the following abnormal conditions:
?100% over-discharge, when the battery has not been used for a long time, or has been over-discharged (the specific gravity of the electrolyte is less than 1.10), you must implement equal charging.
·Battery supplemented with distilled water
After measuring the specific gravity and liquid temperature of all batteries in ?, the specific gravity is converted to the specific gravity at 20℃, and the relative difference exceeds 0.02 or more.
?. Equalized charging is usually implemented once a month. If the discharge is repeated every day, it must be implemented once a week, which has extended the average distribution of power within the battery.
?. It is not possible to switch the auto/equal charging switch during recharging.
p Hazard warning: Hydrogen generated during charging is explosive, so it is strictly forbidden to smoke or fire in the charging area. It is best to make a shelf for the charger to raise it to avoid moisture on the ground and cause damage to the charger.
c. Supplementary electricity:
After the operation is completed, it is implemented when the power is insufficient.
