3 phases for correctly installing traction batteries

Installing an industrial traction battery is a critical task that demands precision and attention to detail. The safety, reliability, and long-term performance of the battery all hinge on this step being carried out correctly. A rushed or improvised job is a direct path to costly mistakes, ranging from avoidable downtime to serious safety hazards. That’s why our Energic Plus experts have laid out the process in a 3-phase, 8-step guide to ensure a safe, correct, and smooth installation every time.

Phase 1: Preparation and planning

Step 1: Location check. Select a well-ventilated, dry and cool area. It’s crucial to have sufficient working space around the battery for maintenance and servicing.

Step 2: Safety and compliance requirements. Ensure you have all the necessary personal protective equipment (PPE) readily available, including safety goggles and gloves. You should also have the appropriate fire-extinguishing equipment for the type of battery you’re working with, as well as an emergency plan. For lead-acid batteries, for example, it is recommended to have an eye-wash bottle at hand. Check the local laws and regulations that apply to the charging area or warehouse.

Step 3: Tools and materials. Gather all the necessary tools (make sure they are insulated), cables, connectors, fluids (demineralised water, if required) and measuring equipment (multimeter and hydrometer).

Phase 2: Placement

Step 4: Placement of the battery. As a traction battery can be quite heavy, use certified lifting equipment, such as a forklift with lifting straps, or battery changing beams designed specifically for this purpose, to place the battery in its designated location. Place the battery on a suitable surface or raise it if necessary.

Step 5: Installation of peripheral equipment. Install the charger close to the battery and ensure that it is correctly earthed. Check that the charger is compatible with the type and capacity of the battery.

Phase 3: Connection and startup

Step 6: Cabling and connection. Connect the battery to the charger and the mains supply using the correct cables. Use a multimeter to check the polarity (positive to positive and negative to negative) before making the final connection. Make sure that all connections are secure and free from corrosion.

Step 7: First check and commissioning. Perform a visual inspection to check for any damage, leaks or loose connections. Switch on the power and start the charger according to the manufacturer's instructions. If present, perform the initial configuration of the Battery Management System (BMS).

Step 8: First full charge cycle. It’s crucial that the first full charge cycle is completed correctly, as this will affect the battery’s service life. Allow the battery to charge fully without interruption. For lead-acid batteries, check the electrolyte level after charging and only top up with demineralised water after approximately 10 cycles at the start, if necessary. Thereafter, check the water level weekly after charging.

Find out even more about Energic Plus

Read some of our other blogs to find out more about industrial batteries, chargers, and advanced battery maintenance solutions from Energic Plus:

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