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Motive Power (Traction) Batteries Preventive Maintenance Scheme

Motive Power (Traction) Batteries Preventive Maintenance Scheme

Key elements of an integrated forklift batteries maintenance scheme:   Visual inspection of the container Visual inspection of the container to identify potential cracks, erosion or electrolyte remnants Visual inspection of the battery cells Visual inspection of the cells for potential cracks, distortion, erosion, electrolyte remnants on their top or surface Visual inspection of the peripheral systems & accessories Visual inspection of the peripheral systems & accessories of the batteries (connectors, plugs, aqua filling systems, air lift systems) Voltage measurement of each cell Measurement of the voltage of all cells and of the battery in order to evaluate their condition. Electrolyte density measurement of each cell Measurement of the electrolyte density per cell in order to evaluate their condition. Tightening of batteries’ interconnections Check and tightening of the cell interconnections in order to reassure the safe and correct operation of the battery Inspection of the charger’s condition Inspection of the correct operation of the charger and of the peripheral parts & accessories (plugs, cables, etc) Watering of each cell (if needed) Check of the level of electrolyte in each cell and watering with distilled water to the levels specified by the manufacturer Cleaning of the surface of each cell Cleaning of the surface of each cell from dust and electrolyte remnants Pumping overflows inside from the container Pumping electrolyte spillages from the metallic container in order to avoid possible erosions of it and damages to the forklift. Poles covering with anti-erosive material Covering of the poles with special material that protects from erosion Technical report Creation of technical report after each visit, by evaluating the measured values, summarizing the... read more
UPS Preventive Maintenance Scheme

UPS Preventive Maintenance Scheme

Uninterruptible Power Supply Systems support a wide range of applications and their operation is often critical for companies. Based on our expertise and knowhow in energy power systems, we provide added value services in order to ensure their correct operation. In this context, we have prepared a checklist which includes all key actions in a preventive maintenance scheme for UPS. More specifically, this chechlist includes: Visual inspection of the Uninterruptible Power Supply System and its batteries Visual inspection of the UPS Check of batteries for cracking, distortion, bad connectors or leakages Visual inspection of grounding Inspection of cooling fans’ operation Electrical measurements Check and measure of voltage (input/output) L1 (L2, L3) N. Check and measure of current (input/output) L1 (L2, L3) N. Check of output frequency Inspection of loads normal distribution per phase Inspection and monitoring of system’s alarms and LEDs Calibration and inspection of thresholds points Functional assessments (By-pass mode) and inspection of switches’ correct functioning Functional testing of UPS to By-pass and maintenance by pass switch Check all switches correct functioning Alarm history recording Software update (if a new version is released) Assessment of the UPS correct temperature & ventilation Inspection and tightening of batteries’ interconnections, of DC circuit and of AC input – output cables Check and tightening of AC cables input – output Check and tightening of batteries interconnections & DC circuit using appropriate tool Inspection of electronic circuits and control cards Gradual closure of the UPS system (optical inspection, cleaning, testing) The optical inspection includes the inspection of displays and other alarms The cleaning will be done after opening the covers, using air suction device (vacuum cleaner) Batteries’ maintenance (cleaning... read more
Tips for correct and safe charging of lead-based forklift batteries

Tips for correct and safe charging of lead-based forklift batteries

Before Charging Always wear your protective equipment Indicatively goggles, face shield, rubber apron and boots Charge the batteries only when they are in need of charging  A point of 20% capacity is recommended The battery should be at approximately room temperature  Never charge a “frozen” or a “hot” battery Before start charging the battery, inspect both the charger, the battery and their handling systems for cracks, worn cables, damaged connectors etc. If you notice any problem fix it immediately – in any case do not proceed with charging The battery charger must match the battery The charger must output the same voltage as the battery Avoid “opportunity charging”, meaning partial charging during breaktimes During Charging Prohibit anything that can ignite the gas, being generated during battery charging E.g. sparks, open flames, smoking, etc. Always allow the battery to complete its charging cycle Check the charger Keep the charging area clean and well equipped Have well-ventilated designated charging areas, with proper battery handling equipment (e.g. overhead hoists, lifting beams, battery racks and cranes) After Charging Water your forklift batteries immediately after charging, only with distilled or de-ionized water Top up each cell separately, but do not overfill Batteries must be kept in a cool and dry place Keep your batteries clean A clean battery is a healthy battery Update your charging and watering log... read more
Motive Power Batteries… DOs and DON’Ts

Motive Power Batteries… DOs and DON’Ts

Do you own or operate an electric lift truck? Are you in charge of keeping motive power batteries in a good shape? Regardless of the battery brand you use, find hereunder a series of Hints & Tips that maximize your batteries’ performance and life span. DO… Select and use batteries of proper capacity Fully charge the battery at the end of each shift Keep the battery clean Always check the electrolyte level Make sure that all connectors are tight (on a monthly basis) Keep the automatic filling system or the air-lift system (if available) in good condition Provide enough ventilation so that hydrogen released from batteries does not accumulate in concentrations greater than 4% by volume Read the battery manufacturer’s installation and operation instruction manual carefully Wear protective equipment (goggles, face shield, rubber apron, and boots) when working on batteries Keep open flames and sparks away from batteries Read and observe all warnings posted in the battery room or published by the battery manufacturer Take prompt action when a problem is indicated Neutralize spilled electrolyte immediately with a solution of 1 kg. baking soda to 4 ltrs of water Apply an equalizing charge once a week Keep accurate records on a regular basis DON’T… Smoke or create sparks near batteries Wear conductive jewellery when working around batteries Lay tools on top of batteries Overcharge batteries Add water before charging; always add water at end of charge Remove the cells vent plugs   SYSTEMS SUNLIGHT S.A. | Motive Power Batteries for Forklifts – Dos and DONTs View more presentations from SYSTEMS SUNLIGHT... read more