Batteries and Charging PDF File

Batteries and Charging PDF File
December 2016
How to care for your batteries
December 2016 / magicmobility.com.au
Contents
How to care for your batteries .................................................................................................................... 1
Initial Care .................................................................................................................................................. 4
Recommendations ..................................................................................................................................... 4
To get the maximum range from your batteries ....................................................................................... 4
PLEASE Note................................................................................................................................................................... 4
Batteries ..................................................................................................................................................... 4
Battery charging
5
Battery run-in
5
Procedure......................................................................................................................................................................... 5
PLEASE Notes................................................................................................................................................................. 5
Charging procedure
5
Battery gauge
6
LED Battery gauge
6
How your battery gauge works: ................................................................................................................................. 7
Public transportation
7
Battery disposal and recycling
7
Public transportation
7
Battery disposal and recycling
8
Gel Battery Performance and Range ......................................................................................................... 8
Further Factors Effecting Battery Energy Available ................................................................................. 9
Questions to be asked if battery life is not meeting expectations
9
Factors that significantly affect the life of a battery
9
Cyclic life.......................................................................................................................................................................... 9
Depth of Discharge (DOD) effect ........................................................................................................................... 10
Temperature effect
10
Recharge voltage and rate
10
Power consumption on batteries
11
Battery Chargers ....................................................................................................................................... 11
ATTENTION, NOT ALL BATTERY CHARGERS ARE CREATED EQUAL
11
Does that charger have a sufficient charging rate to re-charge the battery in a timely manner?
11
Charger performance
11
December 2016 / magicmobility.com.au
Will my charger work in the USA?
December 2016 / magicmobility.com.au
12
Initial Care
Ensure the batteries are fully charged before the first use
During the first 5 cycles, avoid excessive loads (e.g. steep slopes and beaches) and deep discharges
Fully charge the chair, the charger light will turn green
New batteries take longer to achieve full charge and the capacity is reduced; this will improve
Recommendations
Avoid allowing the batteries to get very flat
Charge as soon as possible after flattening
Always fully recharge the batteries (this may take more than 8 hours)
To get the maximum range from your batteries
Ensure that the tyre pressures are correct for the weight and the terrain
Avoid stop-go driving; try to maintain a constant speed
Try to avoid inclines
Limit baggage weight carried
PLEASE NOTE
The charger may not operate if the batteries have been allowed to go completely flat. If this happens, call
your Magic Mobility Dealer for assistance.
Batteries
Your power chair uses a pair of high quality long lasting gel cell batteries that are sealed and maintenance
free. Your power chair has a 24V system which is supplied by two 12V batteries. There is no need to check
the electrolyte fluid level they contain. Despite their similarity to automotive batteries, they are not the
same. Automotive batteries are not designed to handle a long, deep discharge, and are also unsafe for use
in power chairs.
WARNING! Battery posts, terminals, and related accessories contain lead and lead
compounds, wash your hands after touching.
WARNING! Corrosive chemicals are contained in the batteries. Use only AGM or gelcell batteries to reduce the risk of leakage or explosive conditions.
WARNING! When fitting alternate batteries, ensure their terminal posts cannot touch
any part of the wheelchair frame.
December 2016 / magicmobility.com.au
STOP! Automotive batteries and chargers are unsafe for use in power wheelchairs
Battery charging
We recommend using only a high quality intelligent battery charger that is compatible with your power
chair’s batteries. Only use the supplied off-board charger unless otherwise approved by Magic Mobility.
Do not use an automotive-type battery charge.
The charger will not operate after the batteries have been discharged to an extremely low voltage. If this
happens, call your Magic Mobility Dealer for assistance.
Battery run-in
Proper care of the battery during the 'run in' (initial care) period is particularly important for battery life.
PROCEDURE
Ensure the Battery is fully charged before the first use,
Use the chair normally during the day, avoid excessive loads during the first 5 cycles,
Charge the chair fully overnight, checking that the charger indicates that the battery is fully charged
(enters float mode),
Repeat steps 2 and 3 for the first 20 times (cycles) to complete the 'Run in' procedure.
PLEASE NOTE
The new battery will take longer to achieve the full charge, but the time required will improve. Initially you
may find that you have to limit the amount of use during the day for the full charge to be achieved.
The battery capacity is reduced when new, this is normal and will improve during the run-in process.
Charging procedure
Battery Charging is via a socket within the joystick module. When a charger is plugged in, the joystick unit
recognises the unit is plugged in and chair driving is inhibited.
The following procedure is valid for the recommended charger brand - consult your separate charger
instructions if supplied with an alternative charger:
1.
2.
3.
4.
Ensure the wheelchair is turned off
Always make sure that the charger is turned off before plugging it into the wheelchair
Plug the charger into the charging socket on the joystick module
Please consult the instruction manual supplied with your charger for detailed instructions
The following advice is recommended to help care for your batteries:
Avoid ultra-deep discharges (deep discharges reduce cycle life)
Don’t leave batteries at a low state of charge for an extended period of time (e.g. after a day’s use fully
recharge the batteries overnight)
After discharging the batteries to a low state of charge, recharge them fully (this may take more than 8
hours)
December 2016 / magicmobility.com.au
WARNING! Always protect the batteries from freezing and never charge a frozen
battery. Doing so can result in personal injury and damage to the battery.
STOP! Do not put the charger on the seat of the wheelchair when charging as the
charger can become quite warm. Always put the charger on the floor near the chair
when in use.
To get the maximum range from your batteries:
Fully charge the batteries prior to the trip
Ensure that the tyre pressures are correct for the weight and the terrain
Avoid stop-go driving; try to maintain a constant speed
Try to avoid inclines
Limit baggage weight carried
Do not operate the control system if the battery is nearly discharged. Failure to comply with this condition
may leave the user stranded in an unsafe position, such as in the middle of a road. Magic Mobility accepts
no liability for losses of any kind arising from failure to comply with this condition.
Battery gauge
LCD screen Battery Gauge:
The batteries are charged if the battery gauge shows red, yellow and
green
You should charge the batteries as soon as you can if the battery gauge
shows just red and yellow
You should charge the batteries immediately if the battery gauge shows
just red, either steady or flashing slowly
LED Battery gauge
(LEDs 1 – 10)
The batteries are charged if the battery gauge shows red, yellow and
green.
December 2016 / magicmobility.com.au
(LEDs 1 – 7)
You should charge the batteries as soon as you can if the battery gauge
shows just red and yellow
(LEDs 1 – 3)
You should charge the batteries immediately if the battery gauge shows
just red, either steady or flashing slowly
Your battery gauge may also flash in different patterns to indicate your battery’s status:
LEDs on, Steady: This indicates that all is well and displays your level of remaining charge
LEDs Flashing Slowly: The control system is functioning correctly but needs charging
LEDs Light up sequentially, Stepping Up: The wheelchair batteries are being charged. You will not be
able to drive the wheelchair until the charger is disconnected and you have switched the control
system off and on again
HOW YOUR BATTERY GAUGE WORKS:
The battery gauge lets you know how much charge is left in your batteries. The best way for you to use the
gauge is to learn how it behaves as you drive the wheelchair. Like the fuel gauge in a car, it is not
completely accurate, but it will help you avoid running out of “fuel”.
When you switch on the control system, the battery gauge shows an estimate of the remaining battery
charge. The battery gauge gives you a more accurate reading about a minute after you start driving the
wheelchair.
The amount of charge in your batteries depends on the way you use your wheelchair, the temperature of
the batteries and their age. These factors will affect the distance you can travel in your wheelchair. All
wheelchair batteries will gradually lose their capacity as they age.
If your battery gauge reading seems to fall more quickly than usual, your batteries may be worn out. When
you replace worn out batteries, fit the type recommended by Magic Mobility. If you use another type, the
battery gauge may be inaccurate.
Public transportation
The Gel Cell batteries are Federal Aviation Administration (FAA) approved, allowing safe transportation
on aircraft, buses and trains. However, Magic Mobility recommends that any specific requirements of the
carrier are checked in advance. When flying with your wheelchair, please call the airline for any specific
information they need. Magic Mobility has a “flying with your wheelchair” fact sheet on the website that
covers most questions.
Battery disposal and recycling
If you encounter a damaged or cracked battery, contact your Magic Mobility Dealer for instructions on
disposal. Your Magic Mobility Dealer will also have all the necessary information on the recycling of
batteries as well as all other wheelchair parts, which is our recommended course of action.
Public transportation
The Gel Cell batteries are Federal Aviation Administration (FAA) approved, allowing safe transportation
on aircraft, buses and trains. However, Magic Mobility recommends that any specific requirements of the
carrier are checked in advance. When flying with your wheelchair, please call the airline for any specific
December 2016 / magicmobility.com.au
information they need. Magic Mobility has a “flying with your wheelchair” fact sheet on the website that
covers most questions.
Battery disposal and recycling
If you encounter a damaged or cracked battery, contact your Magic Mobility Dealer for instructions on
disposal. Your Magic Mobility Dealer will also have all the necessary information on the recycling of
batteries as well as all other wheelchair parts, which is our recommended course of action.
Gel Battery Performance and Range
The performance of the batteries is affected by many things – it is difficult to give precise range forecasts.
With the X8 and the Frontier All Terrain, a very easy way to improve the range is to pump up the tyres.
However, if you go on the beach or in mud the X8 will perform much better if the tyres are at low pressure.
This kind of activity will make the batteries drain very quickly as the motors are working very hard all the
time.
If you are using the X8 or the Frontier All Terrain on trails or even on the street where the surface is quite
firm, then it is possible to put more air in the tyres. We recommend up to 8psi, but you could maybe go a
little bit more.
With the X8 and the Frontier All Terrain, Magic investigated installing bigger batteries, but we felt that it
was important to maintain the overall size of the chair. So we chose to stay with the 73Ahr. Not only are
the bigger batteries much more expensive they add an enormous amount of weight and negate their own
higher amperage to some degree!
Our electrical engineer reviews the battery market regularly to see if anyone has produced a bigger battery
that will fit in the X8. We also prefer to use Geltech or Sonnenschein batteries. Our experience to date tells
us that they are still a superior battery.
Unfortunately, the nature of the lead acid gel battery means that they will deteriorate with every cycle.
There isn’t much you can do apart from charging them up every night and trying not to let them get too flat
too often.
Batteries are a big investment, and for someone who uses their chair every day, we recommend budgeting
to replace them every 18 months – they might last a bit longer and if they do, that is great!
Follow the tips in the owner’s manual to maximise your batteries:
Follow the run-in procedure
Follow the charging procedure
Your charger is critical, see the information below
Charge the batteries at room temperature
Charge them as soon as possible after a deep discharge
Be temperature aware – batteries don’t like being hot or cold – if you are enjoying afternoon cocktails,
try to get you chair in the shade of the table if you can
December 2016 / magicmobility.com.au
Further Factors Effecting Battery Energy Available
Questions to be asked if battery life is not meeting expectations
Are the batteries brand new?
If so, be aweare that the batteries are ‘lazy’to begin with and take 5-10 cycles before good
performance is achieved.
Have the batteries been looked after since new and all procedures been followed?
Has the recommendation to avoid over discharge been followed?
Have the batteries been charged as soon as possible following when large discharges?
Has the recommendation to fully recharge the batteries after discharge been followed?
Have the batteries only been charged with the correct charger? (see below)
Have the batteries only been charged at moderate temperatures?
The charging voltage/ profile for the charger is designed for charging a battery that is at room
temperature. For maximum battery life and to enable the battery to be charged fully always charge
with the battery at or close to room temperature (batteries have a high thermal mass and are slow
to change temperature)
Are the Batteries Balanced (do they have similar voltage)?
Connecting any devices (e.g. a 12V device) across one battery is strictly forbidden as it will affect
the balancing resulting in incorrect charging voltages at the individual battery
Have the Batteries been protected from excessive temperatures?
Avoiding leaving the chair in the sun in hot weather, etc.? Avoid temperatures below -20C and
above 60C
Are the Connections and Battery Cable Circuits in good condition so that the resistance is low?
Excessive resistance could affect charging, the speed of the Wheelchair, the Efficiency of operation
and may cause the Wheelchairs Electronics to indicate that the Battery is further discharged than
what it actually is
Are there other devices consuming power from the wheelchair batteries?
Is the weight on the chair minimised by avoiding carrying excess baggage?
Are the tyres and tyre pressures appropriate for the terrain and gross weight of the wheelchair?
see the owner’s manual for more information
Does the Wheelchair roll freely without excessive drag?
Check by switching of the controller and disengaging motors, it should be able to be pushed
without an excessive amount of effort on a firm flat surface, try straight ahead and also turning to
the left and right
Factors that significantly affect the life of a battery
CYCLIC LIFE
The battery life is mainly determined by the use cycles of the battery. An AGM or flooded battery may
have a life of 300 to 700 cycles under normal use; however that of a gel battery may be from 500 to 5000
cycles. The battery completes a cycle when it is charged and discharges once. In a solar system, the
December 2016 / magicmobility.com.au
batteries are charged during the day and they are partially discharged during the night. In this case, one
cycle corresponds to one day.
DEPTH OF DISCHARGE (DOD) EFFECT
The harder the battery works, the sooner it will fail. This means that a higher capacity withdrawal would
result in a reduction of life cycle. Here is a table that explains the effect of depth of discharge.
Typical VRLA Battery Cycling Ability vs Depth of Discharge
Typical Life Cycles
Capacity Withdrawn
Gel Battery
AGM or Flooded Battery
100%
450
200
80%
600
250
50%
1000
500
25%
2100
1200
10%
5700
3200
Temperature effect
Temperature is a major factor in battery performance, shelf life, charging and voltage control. At higher
temperatures there is dramatically more chemical activity inside a battery than at lower temperatures.
Therefore, the capacity of a battery is lower when the ambient temperature is too low. (eg. A battery bank
that is a kept outdoor in winter).
For most of the batteries, 65-90 F is the recommended temperature range. In higher temperatures, the
battery cyclic life would significantly reduce. We can conclude that, cold temperature is not good for the
performance of the battery; warmer temperature is not good for the battery life.
Recharge voltage and rate
All lead-acid batteries give off hydrogen from the negative plate and oxygen from the positive plate during
charging. The valve regulated batteries (VRLA) have pressure sensitive valves. Without the ability to retain
pressure within the cells, hydrogen and oxygen would be lost to the atmosphere, eventually drying out the
electrolyte and separators.
A battery can only store a certain quantity of electricity. The closer it gets to being fully charged, the slower
it must be charged.
Typically, the battery would be charged up to 90% in 60% of the overall charging time; the remaining 10%
would take up to 40% the total time. Therefore, it is critical to use a suitable charge controller in order to
regulate the voltage and the charge rate when charging a battery.
Any VRLA battery will dry out and fail prematurely if it experiences excessive overcharge.
It should be noted that, 13.8-14.1 V voltage range would mean a fully charged battery for a Gel type battery
whereas, 14.4- 14.6V voltage range would mean a fully charged AGM battery.
A totally discharged battery is at 11.8-12.0 Volts.
December 2016 / magicmobility.com.au
Power consumption on batteries
The Battery Charger that we use in an efficient Switch Mode Regulated device, which is effective at
reducing the power consumption when the Battery in the wheelchair has reached its charged capacity.
There is very little electricity cost saving to be had by not leaving the wheelchair plugged in. You could
leave a battery on the charger for a year for $18.60, and at the end of it you would still have a fully charged
(and healthy) battery. This is a cost of 0.2 cents/hour based on 25cents/ KWH.
4.5 Watts with no batteries connected
8.5 Watts when connected to batteries and in float mode
Based on $0.25 per kw/h, the annual cost would be around $18 if left on and the charger was in float mode
24/7.
Battery Chargers
ATTENTION, NOT ALL BATTERY CHARGERS ARE CREATED EQUAL
If you need to purchase a charger other than the one that Magic supplies with the chair, you need to check
the following characteristics to ensure that the charger is appropriate for the Geltech Batteries;
Does that charger have a sufficient charging rate to re-charge the battery in a timely manner?
The charger must have a current rate of at least 10% of the 20hour capacity:
The 73AH battery needs a charger of 7.3A or greater. Note, the wheelchair charging circuits are
limited to a maximum continuous charging current of 12A
The 40AH battery needs a charger of 4.0A or greater. Note, the wheelchair charging circuits are
limited to a maximum continuous charging current of 8A
Does the charger have a Boost/ Absorption charge voltage of 27.6 - 28.2V?
Does the charger have a float voltage of 27 - 27.6V?
Please note there can be differences in the recommended charging voltage for other brands of Batteries.
Also note that the charging voltages are appropriate for temperatures close to 25degC. For maximum
battery life avoid charging the chair in locations in which temperature extremes are present (e.g. charging
the chair in a tin shed compared to charging the chair in a temperature controlled area in the house).
If you are in any doubt as to the suitability of your charger, please contact Magic Mobility for assistance
Using an incorrect charger can shorten the life of the battery and void your warranty.
Charger performance
The charger should be able to cope with batteries that have deteriorated.
The charger should go into float mode (drop to 27.4V) when the current drops below 0.3A.
If this is not occurring, then it would either be a fault in the batteries or there is something else that is using
the power.
Note that the charge procedure is to switch off the controller, and this also applies to any other accessories
that are powered from the chairs
December 2016 / magicmobility.com.au
Leaving anything switched on which uses some of the current provided by the charger will delay or prevent
the charger from going into float mode, and this can lead to damage to the batteries by overcharging.
Will my charger work in the USA?
Your wheelchair requires a 24Volt 8Amp Charger.
The charger only operates on 240V so it won’t
work on a USA 110V power point even if you do
have an adapter. To make it work you will need a
‘step up transformer’ such as the one in the
attached image that coverts the 110V power
point to 240V, and it will need a capacity of at
least 400W
http://www.tortech.com.au/category/american
-step-up-transformer-110vac-to-240vacoperate-australian-equipment-in-america
Otherwise you would have to buy a wheelchair
charger that runs on 110V, Soneil make a charger
that will work on 110 or 240 - it is the Zeta-40
2416SR. You will need to bring it into Magic or
have someone fit the correct plug for your
joystick
http://soneil.com/product/model-2416sr/
Contact Magic Mobility if you require further information
2/112 Browns Road, Noble Park Vic 3174
Tel +61 3 8791 5600 Fax +61 3 9701 0144 Email admin@magicmobility.com.au
http://www.magicmobility.com.au
December 2016 / magicmobility.com.au
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertising