Purkey’s Fleet Electric, Inc.Proprietary Information THE PERFECT LIFTGATE BATTERY CHARGING SYSTEM FOR RYDER TRAILERS WITH REEFER AND LIFTGATE

Purkey’s Fleet Electric, Inc. Proprietary Information

THE PERFECT LIFTGATE BATTERY CHARGING SYSTEM

FOR RYDERTRAILERS WITH REEFER

AND LIFTGATE


GOALS

• Provide trailer batteries with maximum charging opportunity

• Automatic system to select the optional charging source

• Protect the tractor batteries from being discharged too low, always start

• Protect the reefer battery from being discharged too low, always start

• System has self diagnostic and operational indicators

• Simple to install, limited components in system


EXISTING SYSTEMS

• SINGLE POLE FROM TRACTOR

• DUAL POLE FROM TRACTOR

• FROM REEFER CHARGING SYSTEM

• TRAILCHARGER


SINGLE POLE

• Single pole charging system consists of one single positive cable connection between the tractor batteries and the trailer batteries, connected with an insulated plug. The ground is totally dependant on how well the fifth wheel is bolted to the frame, and how much contact is being made between the fifth wheel plate and the trailer king pin plate.

[Fifth wheel grease, turning, corrosion, and etc. can impact the ground circuit]


SINGLE POLE DIAGRAM

THROUGH FIFTH WHEEL


DUAL POLE

• Dual pole charging system consists of one single positive cable and one single negative cable connection between the tractor batteries and the trailer batteries, connected with an insulated plug.


DUAL POLE DIAGRAM


DUAL POLE FACTS

• If the dual pole connector is connected, the system is on.• Current can flow both ways.

– If the trailer batteries are defective, most of the current will want to flow to the trailer batteries (path of least resistance).

– Every time the tractor is started, the trailer batteries will try to assist

– If the tractor batteries are defective, most of the current will want to flow to the tractor batteries (path of least resistance).

– Electrical loads left on in the tractor will discharge the trailer batteries

– Electrical loads left on in the trailer will discharge the tractor batteries


DUAL POLE FACTS

• If the dual pole connector is unplugged or not plugged properly, the batteries do not get charged

• Tractor side fuse can be blown, no alert to driver, dual pole plugged in, no charge

• Voltage drop checks are normally not performed• The voltage applied at the trailer batteries is

normally very low• Cold temperatures exacerbates this low voltage

situation• The tractor batteries and trailer batteries do not

share the loads equally


DUAL POLE CHARGING RATE

• The ability for batteries to accept a charge depends on the voltage applied at the battery and the temperature of the battery



10

10.5

11

11.5

12

12.5

13

13.5

14

14.5

15

15.5

16

16.5

17

-22 32 68 104 140 176

10 AMPS - 13.47 V

2.25V @ 0° F

Alternator Voltage 14.0 VTractor Battery Voltage 13.75 V1.42 Volt Drop @ 50 Amps0.0284 Ohms Resistance

Battery Manufacture’s Suggested Charging Voltage At Specific Temperatures

Voltage Applied at Liftgate Batteries @ 10 Amps

° F



10

10.5

11

11.5

12

12.5

13

13.5

14

14.5

15

15.5

16

16.5

17

-22 32 68 104 140 176

30 AMPS - 12.9 V

2.85V @ 0° F

Alternator Voltage 14.0 VTractor Battery Voltage 13.75 V1.42 Volt Drop @ 50 Amps0.0284 Ohms Resistance

Battery Manufacture’s Suggested Charging Voltage At Specific Temperatures

Voltage Applied at Liftgate Batteries @ 30 Amps

° F


FLOODED CELL BATTERY CHARGE ACCEPTANCE AT 0° F


FLOODED CELL BATTERY CHARGE ACCEPTANCE AT 0° F

Charging at 13.5 volts for 1 hour = 1.2 amp/hours




AGM BATTERY CHARGE ACCEPTANCE AT 0° F





FROM REEFER CHARGING SYSTEM

• Method of charging the trailer batteries from the reefer charging system. Trailer batteries are connected in parallel with the reefer battery.


FROM REEFER CHARGING SYSTEM DIAGRAM


TRAILCHARGER

• The trailcharger is used to charge liftgate batteries at a regulated 14.0 volts @ 20 amps in normal temperature (70°F). The trailcharger takes an input voltage between 9.0 volts and 16.0 volts and amplifies/regulates at 14.0 volts output. The trailcharger also used temperature compensation to charge at a higher voltage during colder temperatures. (15.2 volts @ 0°F)


EXISTING TRAILCHARGER DIAGRAM

Connects to the tractor through the aux. pin which is key switched power


THE PERFECT SYSTEM

FOR TRAILERS WITH REEFERS, LIFTGATES, AND INTERIOR LIGHTS


Perfect System Diagram

DUAL POLE CONNECTOR

SYSTEM BOXTRAILCHARGER


DIAGRAM

TRAILCHARGER

REEFER BATTERY

DUAL POLE CONNECTOR

7-WAY

MODULE

SYSTEM BOX

80 amp relays


OPERATION – ENGINE OFF• Aux pin will be low• First five minutes, module keeps magnetic switch closed, still

providing power to trailcharger• Aux pin still low…module looks for ≥ 13.3 volts at reefer. If ≥

13.3 volts, module releases magnetic switch and power up the relay. The reefer now supplies current to the trailcharger

• Module checks reefer battery voltage every two minutes, if <13.3 volts, relay is turned off.

• When reefer/relay is turned off, magnetic switch will stay closed until tractor battery voltage drops to 12.0 volts. Magnetic switch will stay open until tractor is restarted.

• If reefer turns back on and ≥ 13.3 volts, the relay will be powered up again.

• Any time the tractor is started, the order starts over again.


OPERATION – ENGINE ON

• Aux pin is high

• Magnetic switch closed, tractor batteries supplying current to the trailcharger


MATH EXAMPLES

• Liftgate– Time up: 15 seconds– Time down: 15 seconds– Total motor run time per lift: 30 seconds

• 30 seconds ÷ 1 hour = .008334 hours

– Amps up and down: 200 amps• 200 amps x .008334 hour = 1.6668 amp/hours

– 5 lifts per stop (1 hour), Six stops per day• 5 x 6 = 30 lifts per day• 30 lifts x 1.6668 amp/hours = 50.004 amp/hours

– Uses 50 amp/hours per day


MATH EXAMPLES

• Interior Lights– Three florescent lights amp draw: 15 amps– Each stop: 1 hour– Stops per day: 6

• 15 amp/hours x 1 hour = 15 amp/hours• 15 amp/hours x 6 stops = 90 amp/hours

– Uses 90 amp/hours per day


MATH EXAMPLES

• Total used per day: 140 amp/hours• Liftgate = 50 amp/hours• Lights = 90 amp hours


MATH EXAMPLES

• Trailcharger– Output: 20 amps– Daily operation time: 8 hours

• 20 amps x 8 hour = 160 amp/hours

– Provides 160 amp/hours per day


MATH EXAMPLES

• 2 Liftgate batteries– 200 Amp/hours– Battery age and State of charge: <10%>

• 200 amp/hours – 10% = 180 amp/hours

– 180 amp/hours available– 126 amp/hours available at 70% state of charge

• 180 amp/hours – 126 amp/hours = 54 amp/hours

• 54 amp/hours of extra energy


MATH EXAMPLES

• 160 amp/hours (TC) + 54 amp/hours (extra) = 214 AH• 214 amp/hours – 90 amp/hours (lights) = 124 AH• 124 amp hours available for lifts = 74 lifts• 214 amp/hours + 10% (efficiency) = 235 amp/hours• 235 amp/hours – 160 amp/hours (TC) = 75 AH• 75 amp/hours ÷ 20 amp/hours (TC) = 3.75 hours to charge

100% state of charge start of day

Return home Overnight loadingDriving / delivery time

70% state of charge after last lift of day


TESTING DATA

• Test 1– Hot Temperature / 1 Hour / Lights / 5 Lifts ↑↓– Tractor Batteries Charging @ 14.2 Volts– Amp Reading 1 = 25.7 amp/hours of charging– Amp Reading 2 = 14.9 amp/hours of supply– 10.8 amp/hours surplus

LOADAmp reading 2

Amp reading 1

.028 ohms circuit resistance

Tractor batteries

Trailer batteries


TESTING DATA

• Test 2– Hot Temperature / 1 Hour / Lights / 5 Lifts ↑↓– Tractor Batteries Charging @ 13.85 Volts– Amp Reading 1 = 10.4 amp/hours of charging– Amp Reading 2 = 15.3 amp/hours of supply– 0 amp/hours surplus, <4.9> amp/hours behind

LOADAmp reading 2

Amp reading 1

.028 ohms circuit resistance

Tractor batteries

Trailer batteries


TESTING DATA

• MORE TEST DATA COMING

Documents

Purkey’s Fleet Electric, Inc.Proprietary Information THE PERFECT LIFTGATE BATTERY CHARGING SYSTEM FOR RYDER TRAILERS WITH REEFER AND LIFTGATE