THE PERFECT LIFTGATE BATTERY CHARGING SYSTEM FOR RYDER TRAILERS 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

DUAL POLE CHARGING RATE Battery Manufacture’s Suggested Charging Voltage At Specific Temperatures 2.25V @ 0° F 10 AMPS - 13.47 V Alternator Voltage 14.0 V Tractor Battery Voltage 13.75 V 1.42 Volt Drop @ 50 Amps 0.0284 Ohms Resistance Voltage Applied at Liftgate Batteries @ 10 Amps ° F

DUAL POLE CHARGING RATE Battery Manufacture’s Suggested Charging Voltage At Specific Temperatures 2.85V @ 0° F 30 AMPS - 12.9 V Voltage Applied at Liftgate Batteries @ 30 Amps Alternator Voltage 14.0 V Tractor Battery Voltage 13.75 V 1.42 Volt Drop @ 50 Amps 0.0284 Ohms Resistance ° 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 Charging at 14.0 volts for 1 hour = 2.6 amp/hours Charging at 15.0 volts for 1 hour = 4.2 amp/hours

AGM BATTERY CHARGE ACCEPTANCE AT 0° F Charging at 13.5 volts for 1 hour = 2.4 amp/hours Charging at 14.0 volts for 1 hour = 5.2 amp/hours Charging at 15.0 volts for 1 hour = 8.4 amp/hours

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

FOR TRAILERS WITH REEFERS, LIFTGATES, AND INTERIOR LIGHTS THE PERFECT SYSTEM FOR TRAILERS WITH REEFERS, LIFTGATES, AND INTERIOR LIGHTS

Perfect System Diagram DUAL POLE CONNECTOR SYSTEM BOX TRAILCHARGER

DIAGRAM SYSTEM BOX MODULE REEFER BATTERY 7-WAY TRAILCHARGER 80 amp relays DUAL POLE CONNECTOR

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 54 amp/hours of extra energy 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 70% state of charge after last lift of day 100% state of charge start of day Return home Driving / delivery time Overnight loading

TESTING DATA Test 1 Hot Temperature / 1 Hour / Lights / 5 Lifts ↑↓ LOAD Amp reading 2 Amp reading 1 Trailer batteries .028 ohms circuit resistance Tractor batteries 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

TESTING DATA Test 2 Hot Temperature / 1 Hour / Lights / 5 Lifts ↑↓ LOAD Amp reading 2 Amp reading 1 Trailer batteries .028 ohms circuit resistance Tractor batteries 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

TESTING DATA MORE TEST DATA COMING