Prevent Battery Damage + Reduced Cycle Life
To Our Valued Customers,
We hope this finds you, your family, + friends safe + well.
During these unprecedented times, we know many of our customers have had to reduce their workforce or temporarily close their facilities, leaving forklifts + batteries idle. We want to provide you with Hawker Battery instructions to maintain your batteries that have been idle or out of service for more than 3 weeks. To prevent damage + reduced cycle life, batteries must be fully charged prior to extended idle periods. A small amount of additional care is required to ensure each battery achieves maximum life. Due to the differences in construction of Flooded Lead Acid batteries + FLEX Thin Plate Pure Lead batteries (TPPL), separate instructions are required.
Hawker’s Flooded Lead Acid
Flooded lead acid batteries have two major damage mechanisms (sulfation + stratification) if proper care is not taken during a prolonged idle period. Antimony is added to each plate grid for strength + durability. The impact from gaining extra strength is an increased self-discharge rate. Any parasitic loads, such as the BBWC will also discharge the battery. Over time, a lead‐acid battery left in a discharge state will “Sulfate”. A “Sulfated” battery will have reduced capacity + reduced cycle life. Also, over time, the battery Electrolyte will stratify, meaning the heavier Sulfuric Acid will sink to the bottom of the cell, leaving only water on the upper portions of the cell. The highly concentrated acid will attack + destroy the lower portions of the plates within the cell.
Equalize Charge the battery by pressing the manual Equalize button on the charger. The Equalize Charge will ensure that all cells are fully charged + the Electrolyte (Sulfuric Acid + water) is thoroughly mixed. The Electrolyte will be at its maximum level at the end of the Equalize Charge. The Electrolyte should be approximately ¼” from the bottom of the vent well to ensure all plates remain covered during the idle period. Clean the top of the battery with an acid neutralizing agent to prevent extra paths for current flow on the battery. Remove any parasitic loads such as the BBWC, fan, heat blanket + any other battery monitoring devices, to prevent further battery discharge. If the battery has a BBWC installed, simply remove the fuse on the positive lead + tape the fuse to the fuse holder. Leave the battery on an approved battery rack, pallet or simply leave it in its designated truck. If possible, store the battery in a cool dry location, ideally 77°F or 25°C.
Once a month during the idle period, read + record the voltage of each cell in the battery. This is what is referred to as Individual Cell Voltage (ICV). All ICVs should be within 0.04VDC of each other. Determine the cell with the highest + lowest ICV + measure the specific gravity(sg). Also measure the sg of a few random cells in the battery. If any sg is 1.240 or below, or there is a wider variance than 0.04VDC per cell, Boost Charge the battery. Boost Charge is synonymous with manual Equalize Charge. Verify water level after every Boost Charge. Boost Charge the battery every 3 months during the idle period regardless of ICV and sg measurements. If the battery is stored in an area with average temperatures >80°F/27°C, Boost Charge every 2 months because the higher temperatures accelerate self‐discharge + stratification. The purpose is to reverse the effects of self‐discharge + stratification. Verify water level after every Boost Charge. Prior to placing the battery back into service, Boost Charge, verify water level + reconnect all peripheral devices.
Hawker’s FLEX/TPPL
FLEX/TPPL batteries have much longer “shelf‐life” than other types of lead‐acid batteries, but only if the batteries are stored in a fully charged state. Thin Plate Pure Lead (TPPL) refers to the grid composition of pure lead. Since the battery construction does not require stronger plate grids, additives such as Antimony are not required + therefore self‐discharge at a much slower rate. Another benefit of the FLEX battery is the Electrolyte does not stratify because it is suspended in an Absorbed Glass Mat (AGM) which prevents the Sulfuric Acid + water from separating. If you are able to store the FLEX battery within reach of a Hawker FLEX profile charger, simply connect the battery to the charger + leave it. First enable the refresh charge in the configuration setting. The Hawker FLEX profile charger will then constantly monitor the connected battery + will automatically boost the battery when needed.
If you are not able to store the battery next to a Hawker FLEX profile charger, fully charge the battery + press the manual Equalize button on the charger. Upon the completion of the Equalize, verify the top of the battery is clean. Remove all parasitic loads such as the BBWC, fan, heat blanket + any other battery monitoring devices, to prevent further battery discharge. If the battery has a BBWC installed, simply remove the fuse on the positive lead + tape the fuse to the fuse holder. DO NOT DISCONNECT THE LVA. Leave the battery on an approved battery rack, pallet or simply leave it in its designated truck. If possible, ensure the battery is stored in a cool dry location, ideally 77°F or 25°C.
Every 3 months during the idle period, read + record the voltage of each cell in the battery, referred to as Individual Cell Voltage (ICV). If any ICV is 2.12VDC or less, Boost Charge the battery using the Equalize button on the Hawker FLEX profile charger. If the LVA beeps at any time +/or the LED flashes red, Boost Charge the battery. For Bloc batteries, Boost Charge the battery if any individual Bloc is 12.72VDC or less. At the end of the idle period, measure the ICV + charge the battery if any ICV is 2.12VDC or less, then reconnect the peripheral loads. 12.72VDC for individual Blocs.
Flooded Lead Acid Removal from Service:
1. Equalize Charge battery
a. Connect battery to charger
b. Press Equalize button on charger
2. Verify proper electrolyte level upon completion of Equalize Charge
a. Electrolyte level must be above splash guard and approximately ¼” below vent well
b. Add water as necessary per battery instruction manual
3. Disconnect all peripheral devices (parasitic loads)
a. BBWC, remove fuse and tape fuse to fuse holder
b. Any other battery monitoring device
c. Battery fan
d. Battery heat blanket
e. Etc.
4. Clean or wipe down battery with acid neutralizing agent.
5. Place battery in cool dry area (ideal temperature, 77°F, 25°C)
a. On battery rack
b. Or, on a pallet on the floor or suitable rack
6. Monitor battery, monthly
a. Check Individual Cell Voltage (ICV)
b. Test specific gravity on the cells with lowest ICV, highest ICV and 1 or 2 in with the average ICV
c. If any cell has a specific gravity of 1.240 or less, Boost Charge (Equalize Charge) the battery
7. Boost Charge (Equalize Charge) due to battery self‐discharge and electrolyte stratification
a. Average ambient temperature of (>80°F, 27°C), boost every 2 months
b. Average ambient temperature of (<80°F, 27°C), boost every 3 months
Flooded Lead Acid Battery Return to Service:
1. Equalize Charge battery
a. Connect battery to charger
b. Press Equalize button on charger
2. Verify proper electrolyte level upon completion of Equalize Charge
a. Electrolyte level must be above splash guard + approximately ¼” below vent well
b. Add water as necessary per battery instruction manual
3. Reconnect all peripheral devices (parasitic loads)
a. BBWC, replace fuse
b. Any other battery monitoring device
c. Battery fan
d. Battery heat blanket
e. Etc.
FLEX/TPPL Removal from Service:
1. Connect to Hawker FLEX profile charger
a. Enable Refresh charge in configuration settings. The Hawker FLEX profile charger will then automatically Refresh Charge the battery to compensate for the minimal self‐ discharge + parasitic loads.
2. If unable to leave the Hawker FLEX profile charger connected
a. Equalize the battery
• Press Equalize button on the Hawker FLEX profile charger
b. Disconnect all peripheral devices (parasitic loads)
c. BBWC, remove fuse + tape fuse to fuse holder
d. Any other battery monitoring device
e. Battery fan
f. Battery heat blanket
g. Etc.
3. Wipe down top of battery if necessary
4. Place battery in cool dry area (ideal temperature, 77°F, 25°C)
a. On battery rack
b. Or, on a pallet on the floor or suitable rack
5. Every 3 months
a. Check Individual Cell Voltage (ICV)
b. If any ICV is 2.12VDC or less, Boost Charge (Equalize) the battery. 12.72VDC for individual Blocs.
FLEX/TPPL Return to Service:
1. Check Individual Cell Voltage (ICV)
a. If any ICV is 2.12VDC or less, Boost Charge (Equalize) the battery. 12.72VDC for individual Blocs.
2. Reconnect all peripheral devices (parasitic loads)
a. BBWC, replace fuse
b. Any other battery monitoring device
c. Battery fan
d. Battery heat blanket
e. Etc.
