Case Study: The Hidden Dangers of Improper Battery Charging

Key Takeaways

– Case Study: Inadequate Charging Routine

– The Operational Set back at the Facility

– Impacts of Improper Charging

– Proper Charging Practices: What Should Be Done

– Guidelines for Facilities Using Battery-Powered Cleaning Equipment

– Conclusion

It’s just battery charging, what could go wrong? In fact, quite a lot can go wrong if the batteries aren’t charged the right way.

In the fast-paced industrial landscapes, where productivity and performance is the daily reality, batteries are the integral components that make sure the machines are functioning with efficiency.

A recent incident at a food storage facility in the UAE identified a critical flaw in battery charging, which in turn led to major drop in the performance of the cleaning machine, resulting in downtime and eventual battery failure.

This case study analyzes this issue in detail, identifies the source of the issue, its technical consequences and suggests proactive steps to prevent the same.

Case Study: Inadequate Charging Routine

The cleaning machine at the food storage facility was driven by AGM 6V 245Ah batteries, set up in a 24 V system. This battery set up should ideally be charged for at least 12 to 14 hours using a 24V 30 A charger, in order to attain full charge and restore capacity after each use.

Instead, the batteries were charged only for 3 hours per day, which is less than 25% of the recommended time. As this persisted, it caused long term consequences.

The Operational Set back at the Facility

The following were the consequences that hindered the daily cleaning routine at the facility:

• Limited Running Time: The cleaning machines were unable to complete the full cleaning cycle on a single charge. This led to equipment swap or frequent recharging, which significantly reduced productivity.

• Increased downtime: Improper charging weakened the batteries which resulted in the unexpected breakdown of the equipment. This interrupted the daily operations causing high downtime.

• Threat to electronic components: Expensive electronic components such as boards, sensors and drive motors can be damaged in the long run, if the machines are operated at an unstable or low voltage.

The insufficient charging and mismatched charging equipment rendered a costly failure.

Impacts of Improper Charging

Industrial batteries like the AGM model discussed above, are designed for deep discharges and full recharges. These are some of the potential problems caused by improper charging:

• Partial State of Charge (PSOC) and Sulfation

Charging the batteries for just 3 hours a day will leave them in a Partial State of Charge, which over time will lead to the chemical build-up of sulphate crystals on the battery plates, also known as sulfation.

Sulfation causes the plates to harden and eventually blocks them, drastically reducing the battery’s capacity to accept and hold charge. It is one of the major causes of early battery failure.

• Significant Decline in Cycle Life

If maintained properly a normal AGM battery can deliver a range of 300 to 500+ charge cycles.

Repeated undercharging will drastically reduce it to 100-150 cycles. This will cause early battery breakdown, resulting in additional expenses for replacements and maintenance.

• Drop in Voltage During Operation

Batteries, if not fully charged, operate below the optimal voltage levels causing a voltage sag. This can cause the machines to deliver weak performance or even shut down unexpectedly.

Proper Charging Practices: What Should Have Been Done

According to the battery manufacturer recommendations and the service technician’s assessment, the proper charging practices should have been as follows:

• Charging the AGM 6V 245 Ah batteries for at least 12 hours after every use.
• Using the 24V 30A automatic charger that automatically stops when the battery level is full.
• Making sure that the float charge period (which is 2-4 hours after the battery is fully charged) is not omitted, as it helps to stabilize the battery level.

It is also advised to not use the battery unless it is fully charged. Repeated partial discharging will further increase sulfation leading to reduced efficiency.

Guidelines for Facilities Using Battery-Powered Cleaning Equipment

In order to prevent similar complications, the facilities using battery-powered cleaning machines should comply with the following guidelines:

• Educate the staff regarding the battery charging protocols.

• Always use the chargers that are approved by the manufacturers, that matches the battery voltage and amperage specifications.

• Maintain a charging log to ensure full charging cycles.

• Schedule routine maintenance in order to detect the signs of sulfation, voltage drop or reduced capacity at the earliest.

• Utilize smart chargers that effectively monitor the current, voltage and temperature and automatically turn on the float mode once the charging is complete.

Conclusion

A technical oversight in the battery charging almost posed a high business risk for the UAE based facility. Luckily, with the support of SBR Batteries’s expert service team, the issue was promptly detected, technical guidance and charging solution was provided, which helped to regain the machine’s functionality.

Follow the above instructions and make sure the batteries are charged and maintained in the right way.

SBR Batteries are at your service to provide the best customer service and support. Whether it is battery selection, maintenance, charger compatibility or any queries on or about batteries, we are here to assist you and deliver tailored solutions.