Battery Maintenance and Troubleshooting Guide
Battery Maintenance
and Troubleshooting Guide
Proprietary Notice
This manual, including the design and principles of construction disclosed within it, is the
property of Jervis B. Webb Company. It is submitted with the understanding that it is not to be
reproduced, nor copied in whole or in part, nor loaned or otherwise communicated to any third
party, nor used in any manner detrimental to the interests of the Jervis B. Webb Company
without its expressed consent.
The following are registered trademarks or trademarks of the Jervis B. Webb Company (JBW):
SMARTCART®, SAMTM, CARTTOOLS®, SMARTVIEW™, and SMARTSERVER™.
Jervis B. Webb Company
34375 West 12 Mile Road
Farmington Hills, MI 48331-5264
Contact Customer Service at:
1-877-JB-Webb-1 (1-877-529-3221)
webbservice@jerviswebb.com
Document Revisions
Date
Rev. #
Reviser
Description
09-27-13
0.0
JEC
Initial release
10-21-13
1.0
JAW
Major revision of content and format
Document file name is: Battery Maintenance and Troubleshooting Guide Ver 1.0.docx
Date last saved: 10/29/2013
Table of Contents
i
TABLE OF CONTENTS
1
INTRODUCTION..................................................................................... 1
2
BATTERY MAINTENANCE ................................................................. 1
2.1 Daily ...............................................................................................................................1
2.1.1
Auto Charge Systems ...........................................................................................1
2.1.2
Manual Charge Systems ......................................................................................2
2.2 Weekly Finish Charge ....................................................................................................2
2.3 Monthly Finish Charge...................................................................................................2
2.4 Quarterly.........................................................................................................................2
2.5 Semi-Annual (Optional Suggested Testing) ..................................................................2
3
BATTERY MAINTENANCE CHARGE ............................................... 3
4
BATTERY RECOVERY CHARGE....................................................... 4
5
BATTERY TROUBLESHOOTING ....................................................... 5
5.1
5.2
6
Battery Low Level Lockout (Battery Level 0) ...............................................................5
Battery Charger will not Charge Battery........................................................................5
EQUIPMENT FOR BATTERY TESTING AND MAINTENANCE.. 5
ii
Table of Contents
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Battery Maintenance and Troubleshooting Guide
1
1 Introduction
The life of the battery depends on the application and the maintenance schedule. To optimize
battery life, proper maintenance and charging is required. It is also necessary to maintain records
of battery maintenance, as these records are helpful in determining the condition of the battery
(whether it is near the end of its life and needs to be replaced).
WARNING:
FAILURE TO USE THE BATTERY CHARGER SPECIFIED BY
DAIFUKU WEBB FOR THE BATTERY TYPE AND APPLICATION
WILL VOID THE BATTERY WARRANTY.
LACK OF PROPER BATTERY MAINTENANCE WILL ALSO VOID
THE BATTERY WARRANTY.
2 Battery Maintenance
To optimize battery life, the following daily, weekly, monthly, quarterly and semi-annual battery
maintenance schedule should be followed.
2.1 Daily
Daily maintenance requirements are different for manual and automatic charging systems. The
following subsections will explain the specific requirements for each type of system.
CAUTION: Be careful not to over discharge the battery, as this will result in
shortening the life of the battery. Follow battery charging guidelines to ensure
batteries are not over discharged.
2.1.1 Auto Charge Systems
An auto charge system is designed to achieve maximum battery life by charging the batteries
after each transport cycle or series of transport cycles. If a system is operated as designed, no
daily maintenance is required.
Over discharge of the battery can occur if:
•
The SmartCart is manually released and not given a full charge cycle as designed.
•
A SmartCart remains powered up in a system that is not running at designed capacity for
an extended period of time.
To recover from either of the above mentioned situations, check the battery for low life, and then
charge the battery every night.
2
Battery Maintenance and Troubleshooting Guide
2.1.2 Manual Charge Systems
Batteries on a manual charge system should be charged at the end of the day, the shift, or when
the battery is determined to be low (battery level 1). The battery should never be discharged to
low level lockout (battery level 0). Allowing the battery to go to battery low level lockout will
result in shorter battery life or damaged batteries.
2.2 Weekly Finish Charge
Batteries that are not charged for 6-8 hours on a manual charger or allowed to discharge to low
level must be given a finish charge every week. A finish charge brings the level of charge on the
battery to the maximum level, thereby providing optimum battery life.
To achieve a finish charge, charge the batteries for 6-10 hours on a manual charger. Refer to the
Battery Maintenance Charge section for details.
Note: On an automatic battery charge system where the batteries are
charged after 1-3 transport cycles, or series of transport cycles, the
weekly finish charge frequency may be extended to monthly.
2.3 Monthly Finish Charge
On automatic charge system where the batteries are charged after 1-3 transport cycles, a monthly
finish charge is recommended
2.4 Quarterly
Perform a manual charge on the batteries, and then measure and record the following voltage
readings:
•
Voltage of the battery pack as indicated on the HMI.
•
Voltage of each battery as indicated by using a Multimeter.
If there is a significant change of one (1) volt from the readings of the previous month, or a
difference of 0.5 volt in the reading between individual batteries it will be necessary to perform a
recovery charge of the batteries. Refer to the Battery Recovery Charge section for details.
2.5 Semi-Annual (Optional Suggested Testing)
Perform the battery discharge test twice a year to determine the remaining life and condition of
the battery. This is an optional test to prevent possible failure of the battery or low battery
lockout during critical production periods.
Note: Perform a full battery maintenance charge prior to the battery
discharge test, and after the discharge test is completed.
The discharge test must be performed on each battery individually.
Battery Maintenance and Troubleshooting Guide
3
To perform a battery discharge test, proceed as follows:
1. Perform a full maintenance charge of the batteries. Refer to the Battery Maintenance
Charge section for details.
Note: The results of the maintenance charge may require a recovery charge.
2. Disconnect the batteries, and then remove them from the SmartCart.
3. Set the discharge time according to the chart shown below for the specific setting for the
type of battery being tested.
4. Set the discharge shutoff voltage to 1.75 VPC.
5. Set the discharge rate to 25 amps.
6. Wait for the battery discharge test to be completed.
7. Record the minimum voltage, actual voltage, and cycle time in the battery maintenance log.
8. Check the results below to determine what needs to be done:
•
If the cycle time is equal to or less than the minimum cycle time listed in chart below,
the battery is near the end of its life. The battery may continue to function and charge,
but the charge rate and capacity will be reduced. This will result in reduced SmartCart
run time per charge, and the SmartCart will require more frequent charge cycles.
•
If any of the batteries in the battery pack are at or near the end of their life, all the
batteries in the pack should be replaced with new batteries.
Battery
Discharge Time
Setting (minutes)
Enersys TPPL 36 AH
Enersys TPPL 89 AH
Deka AGV 105 AH
75
210
210
Minimum
Cycle Time
(minutes)
34
94
94
3 Battery Maintenance Charge
A maintenance charge will bring a battery pack to full charge, and to a complete charge with a
finish charge cycle. A typical maintenance charge cycle with a finish charge will take 6-10
hours; the duration will vary based on the battery’s initial state of charge.
To perform a battery maintenance charge, proceed as follows:
1. Allow the SmartCart to sit idle for 2 minutes.
2. On the HMI, check the battery pack voltage.
•
If the voltage is greater than 23 volts, place the SmartCart on a manual charger, which
will provide a finish charge of the battery. This charge may take up to 10 hours.
4
Battery Maintenance and Troubleshooting Guide
•
If the voltage is less than 23 volts, perform a battery recovery charge of each battery.
Refer to the Battery Recovery Charge section for details.
3. Select the appropriate charger for your SmartCart/battery listed in the Equipment List
section.
4. Plug the charger into the manual charge connection on the SmartCart.
5. Charge the battery until the charger indicates the charge is complete. Refer to the charger
manual for details on charge features.
Note: If the charger does not turn on, the batteries will need a recovery
charge, or will need to be replaced.
4 Battery Recovery Charge
A recovery charge must be performed if the batteries have been over discharged or sulfated. The
individual battery must be charged independently with a special battery recovery charger.
Any individual 12V battery with a measured voltage of less than 11.5 volts is over discharged
and may be sulfated. If it is determined that one of the batteries in a SmartCart battery pack
needs a recovery charge, all the batteries in the pack should receive a battery recovery charge.
Note: Refer to the charger manual for additional details and cautions for
charging the batteries.
To perform a battery recovery charge, proceed as follows:
1. Remove all connections from the battery.
2. Set the charger mode to 14.7V/3.3A.
3. Connect the charger to the battery following the instructions in the charger manual.
4. Leave the battery on the charger until the Charge Complete green light turns ON.
Note: If the battery does not reach 12 volts in 26 hours, replace the battery.
If the battery temperature reaches 113°F, stop the charge and replace
the battery. (Temperature tabs are available to monitor temperature).
5. Reconnect the batteries in the SmartCart.
6. Perform a maintenance charge on the battery pack. Refer to the Battery Maintenance
Charge section.
Battery Maintenance and Troubleshooting Guide
5
5 Battery Troubleshooting
5.1 Battery Low Level Lockout (Battery Level 0)
Battery lockout is a condition where the SmartCart has determined that the battery voltage has
dropped to the low level limit. Operation of the SmartCart under these conditions will result in
reduced battery life, damage to the battery, and poor automatic operation of the vehicle. The
battery must be charged.
Note: The SmartCart can be moved to the battery maintenance charge area
using a manual pendant.
To recover following a low battery lockout, proceed as follows:
1. Allow the SmartCart to sit idle for 2 minutes.
2. On the HMI, check the battery pack voltage.
5.2
•
If the voltage is greater than 23 volts, place the SmartCart on a manual charger, which
will provide a finish charge of the battery. This charge may take up to 10 hours. Refer to
the Battery Maintenance Charge section for details.
•
If the voltage is less than 23 volts, perform a battery recovery charge of each battery.
Refer to the Battery Recovery Charge section for details.
Battery Charger will not Charge Battery
Batteries may become over discharged or sulfated as the batteries become older. In a manual
charge system the frequency of required battery charges will increase as the batteries age, which
may result in over discharged or sulfated batteries. If the manual or automatic charger will not
turn on, or comes on and quickly turns off, a recovery charge is needed. Refer to the Battery
Recovery Charge section for details.
6 Equipment for Battery Testing and Maintenance
Battery Type
Maintenance /
Finish Charger
Enersys TPPL 36 AH
Enersys TPPL 89 AH
Webb #C1113218
Deka AGV 105 AH
Webb #C1097215
Recovery Charger
for Single 12v
Battery
Webb #C1113732
Battery Tester
for Single 12v
Battery
Webb #C1113731
6
Battery Maintenance and Troubleshooting Guide
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