Contents

HEAVY DUTY
TRACTION BATTERY & CHARGER

Topics
• BRIEF OVERVIEW

• HOW BATTERIES WORK

• OPERATIONS & MAINTENANCE

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 TRACTION BATTERY

What is a BATTERY?
A roll of cells connected in series to store electrical energy in
the form of chemical energy

How does a Lead-Acid Battery work?

•Two dissimilar electrodes are immersed in electrolyte (dilute sulfuric acid) to form a ‘CELL’.
•The CELL stores Chemical energy.
•When an electrical circuit is made between the positive and negative electrodes, a chemical reaction occurs within the
cell and a DIRECT CURRENT is driven through the circuit.
•Lead-Acid cells have a nominal Voltage of 2 Volts, irrespective of the size of the cell, no. Of electrodes (i.e. Plates)
and quantity of acid in the cell.
•The cells are usually connected in series to obtain any higher desired higher voltage.

Battery Voltage = (No. Of cells in series) x 2

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 TRACTION BATTERY
Best Traction Batteries are made of
•TUBULAR Positive Plates
•Special Microporous Separators.
•Assembled in Heat-Sealed plastic containers.
•Low resistance Inter-Cell Connectors.
•Electrolyte level Indicators or Sensors.
•Insulating covers over all ‘LIVE’ parts.

Electrical Energy
•The practical unit is “Kilo Watt Hour”(KWh)
•KWh = Volts x Amps x Hours.
•Hence, electrical energy stored in a battery is usually defined in
terms of AMPERE HOURS (Amps x Hours).
•A battery must be specified in terms of VOLTAGE and
AMPERE HOUR (AH) capacity.

AH Capacity depends upon:

•The no. Of Plates in a cell.
•The construction of the plates.
•The dimensions of each plate.

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 TRACTION BATTERY
OPERATION OF CEIL TRACTION BATTERIES IN EXTREME
AMBIENT TEMPERATURES
COLD TEMPERATURE OPERATION - COLDROOM
Following factors affect the electrolyte temperature which determines the capacity of the battery
•electrolyte temperature when the truck enters the cold room
•the length of time that the truck operates in the cold room
•size and layout of the cells
•degree of the thermal insulation of the battery compartment and its exposure to the air stream
passing over the truck
Under normal circumstances batteries are charged in warmer areas (32° to 38°)
•electrolyte temperature at the beginning is likely to be the same
•for average sized batteries at ambient of ~-6°C, the temperature slowly during a shift is
around 10°C at the end of 8 hour shift

IN THESE CIRCUMSTANCES, THE BATTERY GICES ONLY SLIGHTLY LESS THAN ITS
RATED CAPACITY, BUT IF OPERATING IN LOWER TEMPERATURES THEN ADEQUATE
INSULATING MEASURES HAVE TO BE TAKEN TO RETAIN AS MUCH GENERATED
DURING RECHARGING AS POSSIBLE.

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 TRACTION BATTERY
OPERATION OF CEIL TRACTION BATTERIES IN NORMAL
AMBIENT TEMPERATURES
NORMAL AMBIENT TEMPERATURE OPERATION

•At high temperatures, the capacity increases but the corrosion of the plates are greatly enhanced,
reducing life

•It is recommended that where ambient frequently exceed 35°C, the electrolyte SG for full charged
cells be reduced to 1.250-1.260

•Electrolyte temperature should not exceed 50°C ( Proper ventilation of the battery should be there )

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 TRACTION BATTERY
WORKING THEORY OF CEIL MOTIVE POWER TRACTION
BATTERIES
CHEMICAL REACTION
DISCHARGE
Lead Sulfate forms on both positive and negative plates, resulting in

•A fall in specific gravity of the electrolyte

•A fall in cell voltage

•During this process the cell Gives Out energy

CHARGE
Lead Sulfate us converted into lead peroxide at the positive plates, and into spongy Lead at the negative,
which results in:

•a rise in specific gravity of the electrolyte

•A rise in cell voltage during this process the cell Absorbs out energy

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 TRACTION BATTERY

CHEMICAL REACTION (Before Discharge)

Positive Plate Electrolyte Negative Plate

Lead Peroxide + Battery Water + Lead

CHEMICAL REACTION (After Discharge)

Positive Plate Electrolyte Negative Plate
Lead sulphate + Water + Lead Sulphate

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 TRACTION BATTERY

ACID AND WATER FOR USE IN CELLS

Pure dilute sulfuric acid should be used for filling the cells. The actually standard of purity required for the
acid is given in British Standard 3031: 1972 which specifies the following impurity levels in 1.215 specific
gravity acid at 20°C.

MIXING AND DILUTING SULPHURIC ACID (TO BE DONE BY BATTERY

SUPPLIER)
The approximate quantities of water required dilute strong acid is given below, but some minor adjustments may
be necessary.

Specific Gravity (SG. Level) : 1.215 specific gravity acid @ 20°C

Initial Specific Gravity Final Specific Gravity Approximate proportions, by
volume, of sulfuric acid and water

1.840 1.280 1 part of acid to 3 parts of water

1.840 1.250 1 part of acid to 3 ½ parts of water
1.840 1.400 1 part of acid to 1 ½ parts of water
1.840 1.220 1 part of acid to 4 parts of water
1.840 1.190 1 part of acid to 5 parts of water
1.400 1.280 2 parts of acid to 1 part of water
1.400 1.250 3 parts of acid to 2 parts of water
1.400 1.220 1 part of acid to 1 part water
1.400 1.190 4 parts of acid 5 acids of water

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 TRACTION BATTERY
TROUBLESHOOTING
FAULT REASON ACTION

Erratic end of charge specific gravity and voltage Too little charge. Extend the recharge. Check charger operations.

Electrolyte spillage evident normally through After normal recharge adjust electrolyte as set out in
corrosion of battery box. procedure on Adjustment of Acid

Cell fault. Replace cells, if defective.

Battery Overheating Water cycle too intensive Build cooling periods into operation. Open battery
compartment when charging. Apply forced
ventilation to battery, if possible.
Charger malfunction
Too frequent charging Check operation of charger. Examine operation and
reduce frequency of recharging.

Battery not completing work schedule Not fully charged. Erratic or low end of charges Extend the charge.
reading.

Battery too small. End of charge readings regular but Note end of discharge reading. If below 1.150
low. examine operation, as current draw from motor is
probably excessive and can be improved by training
Battery aging the driver how to conserve energy.

Consider battery replacement.

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 TRACTION BATTERY

FACTORS AFFECTING TRACTION BATTERY SERVICE LIFE

CHARGING CURRENT

Higher charging currents than ones recommended would cause rise in electrolyte temperature, which will
enhance the corrosion of the plates.

RECHARGE VOLUME IN AMPERE HOURS

Recharging should amount to 110% of the ampere hours consumed during discharge, Any over or
undercharging brings down battery life.

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 TRACTION BATTERY CHARGER

Available Types

•CONSTANT CURRENT CHARGER

•TAPER CHARGER
Battery Charger
Battery Selection
Battery’s Performance, Efficiency,
Reliability and Life depends on the Battery
•Voltage of Equipment Charger

•Ampere Hour Capacity – Work Pattern

•Space Availability

•Weight – for stability of vehicle

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 TRACTION BATTERY CHARGER

Charger Selection

•AH Capacity of the Battery to be charged

•Battery Voltage

•AC power supply Voltage, 1 or 3 phase and frequency (Hz)

•Hours available for recharging battery

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 Maintenance Tips

•Top-up once after about 14 shifts.

•Distilled or De-ionized water only to be added, before charging, till just covers the
Separators.

•Cells can be fitted with Float-Indicator Vent Plug, Auto-Filling system or Electronic Level
Sensor.

•Check electrolyte Specific Gravity of all cells with Hydrometer.

•Dissimilar S.G. in cells of a battery may be corrected by prolonged Equalizing Charge

followed by Acid-Adjustment – if cells are healthy.

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 SAFETY – TRACTION BATTERY AND CHARGER

1. Wear gloves, goggles and shoes

2. Do not smoke or use naked flame near battery

3. Always use insulated tools

4. Do not wear watch or jewelry

5. Preferably recharge battery at end of shift when discharge is complete

6. Use only rightly matched Charger

7. Charge batteries in well ventilated space

8. Switch-off Charger before connecting or disconnecting battery

9. Keep battery cover open when charging the battery

10. Ensure that Battery and Charger Connector-Socket colors are the same before connecting them

11. Lift battery only by the lifting-holes provided, keep battery vertical and secure battery position properly before
releasing its weight

12. If acid is spilt –

On Floor: Neutralize with an alkali, Sodium Carbonate or Sodium Bicarbonate powder.
On Clothes: Wash out with water
On Body: Wash immediately with plenty of running water.

****If acid is accidentally splashed into eyes— Wash thoroughly with copious quantities of water and immediately seek
medical attention.

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 In conclusion—

The battery must be kept clean, topped-

up and charged.

It should be on a routine maintenance

schedule.

This will improve RELIABILITY,

EFFICIENCY and EXTENDED LIFE.

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 New Model – BOA LEGLESS

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 New Model – CONDA STACKER

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 OTHER PRODUCT

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