Download 2008-11-12--08-52-51-

THE PERFECT LIFTGATE
BATTERY CHARGING SYSTEM
FOR RYDER
TRAILERS WITH REEFER
AND LIFTGATE
Purkey’s Fleet Electric, Inc.
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GOALS
• Provide trailer batteries with maximum charging
opportunity
• Automatic system to select the optional charging
source
• Protect the tractor batteries from being discharged
too low, always start
• Protect the reefer battery from being discharged
too low, always start
• System has self diagnostic and operational
indicators
• Simple to install, limited components in system
Purkey’s Fleet Electric, Inc.
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EXISTING SYSTEMS
•
•
•
•
SINGLE POLE FROM TRACTOR
DUAL POLE FROM TRACTOR
FROM REEFER CHARGING SYSTEM
TRAILCHARGER
Purkey’s Fleet Electric, Inc.
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SINGLE POLE
• Single pole charging system consists of one
single positive cable connection between the
tractor batteries and the trailer batteries,
connected with an insulated plug. The ground is
totally dependant on how well the fifth wheel is
bolted to the frame, and how much contact is
being made between the fifth wheel plate and
the trailer king pin plate.
[Fifth wheel grease, turning, corrosion,
and etc. can impact the ground circuit]
Purkey’s Fleet Electric, Inc.
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SINGLE POLE DIAGRAM
THROUGH FIFTH WHEEL
Purkey’s Fleet Electric, Inc.
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DUAL POLE
• Dual pole charging system consists of one
single positive cable and one single
negative cable connection between the
tractor batteries and the trailer batteries,
connected with an insulated plug.
Purkey’s Fleet Electric, Inc.
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DUAL POLE DIAGRAM
Purkey’s Fleet Electric, Inc.
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DUAL POLE FACTS
• If the dual pole connector is connected, the system is on.
• Current can flow both ways.
– If the trailer batteries are defective, most of the current will want to
flow to the trailer batteries (path of least resistance).
– Every time the tractor is started, the trailer batteries will try to
assist
– If the tractor batteries are defective, most of the current will want
to flow to the tractor batteries (path of least resistance).
– Electrical loads left on in the tractor will discharge the trailer
batteries
– Electrical loads left on in the trailer will discharge the tractor
batteries
Purkey’s Fleet Electric, Inc.
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DUAL POLE FACTS
• If the dual pole connector is unplugged or not
plugged properly, the batteries do not get charged
• Tractor side fuse can be blown, no alert to driver,
dual pole plugged in, no charge
• Voltage drop checks are normally not performed
• The voltage applied at the trailer batteries is
normally very low
• Cold temperatures exacerbates this low voltage
situation
• The tractor batteries and trailer batteries do not
share the loads equally
Purkey’s Fleet Electric, Inc.
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DUAL POLE CHARGING
RATE
• The ability for batteries to accept a
charge depends on the voltage applied at
the battery and the temperature of the
battery
Purkey’s Fleet Electric, Inc.
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DUAL POLE CHARGING RATE
17
16.5
16
15.5
15
14.5 2.25V
14 @ 0° F
13.5
13
12.5
12
11.5
11
10.5
10
-22
Battery Manufacture’s
Suggested Charging Voltage
At Specific Temperatures
10 AMPS - 13.47 V
Alternator Voltage 14.0 V
Tractor Battery Voltage 13.75 V
1.42 Volt Drop @ 50 Amps
0.0284 Ohms Resistance
32
Purkey’s Fleet Electric, Inc.
68
104
Voltage Applied at Liftgate
Batteries @ 10 Amps
140
176
°F
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DUAL POLE CHARGING RATE
17
16.5
16
15.5
15
14.5 2.85V
14 @ 0° F
13.5
13
12.5
12
11.5
11
10.5
10
-22
Battery Manufacture’s
Suggested Charging Voltage
At Specific Temperatures
30 AMPS - 12.9 V
Alternator Voltage 14.0 V
Tractor Battery Voltage 13.75 V
1.42 Volt Drop @ 50 Amps
0.0284 Ohms Resistance
32
Purkey’s Fleet Electric, Inc.
68
104
Voltage Applied at Liftgate
Batteries @ 30 Amps
140
176
°F
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FLOODED CELL BATTERY
CHARGE ACCEPTANCE AT 0° F
Purkey’s Fleet Electric, Inc.
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FLOODED CELL BATTERY
CHARGE ACCEPTANCE AT 0° F
Charging at 13.5 volts for 1 hour = 1.2 amp/hours
Charging at 14.0 volts for 1 hour = 2.6 amp/hours
Charging at 15.0 volts for 1 hour = 4.2 amp/hours
Purkey’s Fleet Electric, Inc.
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AGM BATTERY CHARGE
ACCEPTANCE AT 0° F
Charging at 13.5 volts for 1 hour = 2.4 amp/hours
Charging at 14.0 volts for 1 hour = 5.2 amp/hours
Charging at 15.0 volts for 1 hour = 8.4 amp/hours
Purkey’s Fleet Electric, Inc.
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FROM REEFER CHARGING
SYSTEM
• Method of charging the trailer batteries
from the reefer charging system. Trailer
batteries are connected in parallel with the
reefer battery.
Purkey’s Fleet Electric, Inc.
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FROM REEFER CHARGING
SYSTEM DIAGRAM
Purkey’s Fleet Electric, Inc.
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TRAILCHARGER
• The trailcharger is used to charge liftgate
batteries at a regulated 14.0 volts @ 20 amps
in normal temperature (70°F). The trailcharger
takes an input voltage between 9.0 volts and
16.0 volts and amplifies/regulates at 14.0 volts
output. The trailcharger also used
temperature compensation to charge at a
higher voltage during colder temperatures.
(15.2 volts @ 0°F)
Purkey’s Fleet Electric, Inc.
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EXISTING TRAILCHARGER
DIAGRAM
Connects to the tractor through the
aux. pin which is key switched power
Purkey’s Fleet Electric, Inc.
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THE PERFECT SYSTEM
FOR TRAILERS WITH REEFERS,
LIFTGATES, AND INTERIOR LIGHTS
Purkey’s Fleet Electric, Inc.
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Perfect System Diagram
DUAL POLE CONNECTOR
SYSTEM BOX
TRAILCHARGER
Purkey’s Fleet Electric, Inc.
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DIAGRAM
SYSTEM BOX
MODULE
REEFER BATTERY
7-WAY
TRAILCHARGER
80 amp
relays
DUAL POLE
CONNECTOR
Purkey’s Fleet Electric, Inc.
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OPERATION – ENGINE OFF
• Aux pin will be low
• First five minutes, module keeps magnetic switch closed, still
providing power to trailcharger
• Aux pin still low…module looks for ≥ 13.3 volts at reefer. If ≥
13.3 volts, module releases magnetic switch and power up
the relay. The reefer now supplies current to the trailcharger
• Module checks reefer battery voltage every two minutes, if
<13.3 volts, relay is turned off.
• When reefer/relay is turned off, magnetic switch will stay
closed until tractor battery voltage drops to 12.0 volts.
Magnetic switch will stay open until tractor is restarted.
• If reefer turns back on and ≥ 13.3 volts, the relay will be
powered up again.
• Any time the tractor is started, the order starts over again.
Purkey’s Fleet Electric, Inc.
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OPERATION – ENGINE ON
• Aux pin is high
• Magnetic switch closed, tractor batteries
supplying current to the trailcharger
Purkey’s Fleet Electric, Inc.
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MATH EXAMPLES
• Liftgate
– Time up: 15 seconds
– Time down: 15 seconds
– Total motor run time per lift: 30 seconds
• 30 seconds ÷ 1 hour = .008334 hours
– Amps up and down: 200 amps
• 200 amps x .008334 hour = 1.6668 amp/hours
– 5 lifts per stop (1 hour), Six stops per day
• 5 x 6 = 30 lifts per day
• 30 lifts x 1.6668 amp/hours = 50.004 amp/hours
– Uses 50 amp/hours per day
Purkey’s Fleet Electric, Inc.
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MATH EXAMPLES
• Interior Lights
– Three florescent lights amp draw: 15 amps
– Each stop: 1 hour
– Stops per day: 6
• 15 amp/hours x 1 hour = 15 amp/hours
• 15 amp/hours x 6 stops = 90 amp/hours
– Uses 90 amp/hours per day
Purkey’s Fleet Electric, Inc.
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MATH EXAMPLES
• Total used per day: 140 amp/hours
• Liftgate = 50 amp/hours
• Lights = 90 amp hours
Purkey’s Fleet Electric, Inc.
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MATH EXAMPLES
• Trailcharger
– Output: 20 amps
– Daily operation time: 8 hours
• 20 amps x 8 hour = 160 amp/hours
– Provides 160 amp/hours per day
Purkey’s Fleet Electric, Inc.
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MATH EXAMPLES
• 2 Liftgate batteries
– 200 Amp/hours
– Battery age and State of charge: <10%>
• 200 amp/hours – 10% = 180 amp/hours
– 180 amp/hours available
– 126 amp/hours available at 70% state of charge
• 180 amp/hours – 126 amp/hours = 54 amp/hours
• 54 amp/hours of extra energy
Purkey’s Fleet Electric, Inc.
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MATH EXAMPLES
•
•
•
•
•
•
160 amp/hours (TC) + 54 amp/hours (extra) = 214 AH
214 amp/hours – 90 amp/hours (lights) = 124 AH
124 amp hours available for lifts = 74 lifts
214 amp/hours + 10% (efficiency) = 235 amp/hours
235 amp/hours – 160 amp/hours (TC) = 75 AH
75 amp/hours ÷ 20 amp/hours (TC) = 3.75 hours to charge
100%
state of
charge
start of
day
Driving / delivery time
Purkey’s Fleet Electric, Inc.
70%
state of
charge
after
last lift
of day
Return
home
Overnight loading
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TESTING DATA
LOAD
Amp
reading 2
Amp
reading 1
Trailer
batteries
.028 ohms circuit resistance
• Test 1
Tractor batteries
– Hot Temperature / 1 Hour / Lights / 5 Lifts ↑↓
– Tractor Batteries Charging @ 14.2 Volts
– Amp Reading 1 = 25.7 amp/hours of charging
– Amp Reading 2 = 14.9 amp/hours of supply
– 10.8 amp/hours surplus
Purkey’s Fleet Electric, Inc.
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TESTING DATA
LOAD
Amp
reading 2
Amp
reading 1
Trailer
batteries
.028 ohms circuit resistance
• Test 2
Tractor batteries
– Hot Temperature / 1 Hour / Lights / 5 Lifts ↑↓
– Tractor Batteries Charging @ 13.85 Volts
– Amp Reading 1 = 10.4 amp/hours of charging
– Amp Reading 2 = 15.3 amp/hours of supply
– 0 amp/hours surplus, <4.9> amp/hours behind
Purkey’s Fleet Electric, Inc.
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TESTING DATA
• MORE TEST DATA COMING
Purkey’s Fleet Electric, Inc.
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