Conley Services

Battery Service And Maintenance

Planned Maintenance For Batteries and Chargers
Planned maintenance is recommended to achieve longer life, improve run times per shift and to keep your equipment safe.  Planned maintenance is performed at customer site. Planned maintenance helps prevent small problems from becoming large problems.

Battery watering is vital to the health of a battery. Many operations are not equipped to safely water batteries. Watering plans are available at customer request. Watering includes a trained service technician, battery extraction equipment and safety equipment. This plan is designed to keep your batteries properly watered and remove the risk to your associates.

How Often Is Planned Maintenance Recommended?
The frequency of planned maintenance is based on the severity and usage of the equipment. The most common plans are quarterly or semi-annually.  Custom plans are available.

Battery And Charger Evaluations

Battery and charger evaluations can be completed at customer site or at our facility. You may find an evaluation beneficial in determining whether you can repair your existing equipment or will need new equipment.  There are many ways batteries and chargers can be repaired.  Evaluations can determine the facts about the state of your equipment. Evaluation include visual inspections, cell voltage readings, specific gravity reading, load testing and many other options to assist in making a decisions on how to proceed.

When To Evaluate

When Should A Battery Or Charger Be Evaluated?
Battery and charger evaluations should be completed any time unusual activity is happening with the equipment. You may find benefit in having equipment evaluated on an annual basis before small problems become larger problems. You may want to have batteries and chargers evaluated before you purchase used lift equipment. In our experience, we have talked to a sizable number of people that purchased used lift equipment to find later the battery or charger was not in good condition.

Battery Clean, Neutralize and Wash

Wet cell industrial batteries contain sulfuric acid.  Sulfuric acid is designed to be contained within the battery cells.  There are a number of ways sulfuric acid can escape the battery cells and move to the battery surface.  This may be caused by overwatering, boiling over the battery during the charge cycle, cracked cell jars among other reasons.  As a result, corrosion will build on the battery surface. It is import to remove the corrosion from the battery surface as it typically contains sulfuric acid.  Corrosion on the battery surface poses health risks, is damaging to battery and lift equipment components, will damage clothing and can reduce battery life and run time per shift.

How Often Should A Battery Be Cleaned, Neutralized and Washed?

This is mainly dependent on the daily operating procedures and the environment the equipment is used in. Sound charging and watering practices will reduce the need for battery cleaning. A sure sign of batteries in need of cleaning is when corrosion deposits are built up on the battery surface. The corrosion buildup is a high concentration of acid.

Battery Acid Adjustment

Sulfuric acid is a critical component of the daily operation of a battery.  Each battery cell has a mixture of sulfuric acid and water.  Specific gravity is the measurement of the acid and water mix.  New batteries from the manufacturing plant are set with the correct specific gravity.  As a battery is charged and discharged the specific gravities can get out of alignment. This happens do to over watering, boiling over batteries, under charging, cracked jars and other reasons. A battery acid adjustment brings the specific gravity back to the recommended range. Acid adjustment can enhance run time, reduce cycles and increase battery life.

What Are Commons Signs Of Batteries In Need Of Acid Adjustment?

There are a number of signs when a battery needs an acid adjustment. Acid does not evaporate like water.  It will be in the battery cell until an event happens.

  • Look for steaks running down the side of a battery.
  • Corrosion buildup on battery surface
  • Reduction in battery run time
  • Battery may omit an odor

 Battery Load Capacity Testing

A battery load capacity test is one of the best methods to determine the overall condition of a battery. The capacity test provides valuable information for making decisions on repairs or replacement. Load capacity tests include equalize charge, hourly cell voltage readings while under load, specific gravity readings, evaluation and recommendations.  The goal of the load capacity test is to determine the exact condition of the battery.  Repairs or replacement are determined by the results of this test. Battery repairs are typically much less expensive than purchasing a new battery. Test results will give an indication of when the battery may need replaced. This will assist in capital expenditure planning.

When Should A Battery Be Load Capacity Tested?

Most of our customer load capacity test a battery when it is underperforming. As batteries age they naturally loose capacity or run time.  This is a good time to have the battery tested.  The capacity test will give you information if the battery can be repaired, adjusted or should be replaced. It is recommended to have batteries tested if the battery has positive plate growth, cracking or corrosion, battery is omitting an odor, dry cell, not accepting a charge.  Test results help determine future capital expenditures.

You may want to consider testing a battery prior to purchasing a used forklift.  This will help you confirm the quality of the product you are purchasing.

Battery Cell Replacement

Industrial batteries are manufactured with battery cells.  Most lift equipment batteries consist of 12, 18 or 24 cells.  The respective battery voltage are 24, 36, and 48 volt. Spent or bad cells can be removed and replaced with reconditioned or new battery cells. Cell replacement is significantly less costly than replacing the battery. Cell replacement will extend the life of your existing battery.

When Should A Battery Cell Be Replaced?

Identifying battery cells in need of replacement is typically identified through cell voltage readings or through the load capacity test.  You may notice bad cells when the battery is underperforming. It is favorable to the overall health of the battery to remove bad cells before they impact good cells.

Cables, Connectors and Contacts

It is not uncommon for cables, connectors and contacts to become worn or damaged. Electricity is moved to and from the battery charger, battery and lift equipment through these components. For safety and operating reasons it is beneficial to keep this equipment in good operating order. Repair and replacement can be completed at customer site or at the Conley facility.

When Do These Components Need Repaired Or Replaced?

Cables should be repaired when copper cable is exposed.  This is completed with a heat shrink material.  In the event a large area of copper is exposed cable should be replaced.  Heat generated from electricity will warp cable coating, cable should be replaced. Pitting occurs to contacts when connectors are disconnected prior to turning off charger. Contacts should be replace when pitting has occurred.

Charger Service And Maintenance

Battery Charger Field Services

Battery charger repairs can be completed on site or at Conley’s location. Battery chargers carry high voltage electrical power.  Typical voltages range from 208 to 480 volt. It is important to very careful around high voltage electrical power. Conley technician are trained, knowledgeable, ARC flash approved and carry ARC flash Gear. If you do not have trained personnel we recommend you contact Conley for charger service.

How Do You Identify Charger Related Problems?

Typically you can identify battery charger related problems because the charger will not charge the battery. In certain cases it will charge the battery at a much slower rate than normal. Chargers may become noisy.

Battery Charger Sizing

Correctly sizing battery chargers to the batteries is very important to the lifespan and health of the battery.  Too large of charger will over charge the battery.  Too small of charger will under charge a battery. In either case you can expect a shorter life span for the battery.
We offer a service to do a site survey to properly size the charging system to the application and the battery size.

How Should Battery Chargers Be Sized?
There are many different types and sizes of battery chargers.  Chargers have a range in which they were designed to work within.  Contact Conley D.C. Solutions for sizing information.

Battery Charger Setup And Electrical Connection
Battery chargers are manufactured in single phase and 3 phase power settings.
They can be set to various building inputs.  Typical inputs are 208, 240 and 480 Volt.
The phase cannot be changed.  The input setting can be changed.
Please give us a call if you need assistance setting your charger.

Battery Charger Planning
Battery chargers have an important role in the overall success of your operation.
In part, your monthly electrical bill will be determined by the type of battery charger you are using.
There are new high efficiency battery chargers available on the market.
Chargers determine if your batteries are properly charged, ultimately impacting the usable life of the battery.
Chargers combined with the batteries will determine how many hours a day your lift equipment can run.
Usable lift truck hours equates to more available hours for lift truck operators to be productive.
Site surveys are available to assist you in specifying the precise equipment to benefit your operation.

Reduce Costs, Extend Equipment Life
Please Feel Free To Contact Us At (303) 296-0320