1. THE PERFECT LIFTGATE BATTERY CHARGING SYSTEM FOR RYDER
TRAILERS WITH REEFER AND LIFTGATE

2. 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

3. EXISTING SYSTEMS SINGLE POLE FROM TRACTOR DUAL POLE FROM TRACTOR
FROM REEFER CHARGING SYSTEM
TRAILCHARGER

4. 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]

5. SINGLE POLE DIAGRAM
THROUGH FIFTH WHEEL

6. 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.

7. DUAL POLE DIAGRAM

8. 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

9. 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

10. 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

11. DUAL POLE CHARGING RATE
Battery Manufacture’s Suggested Charging Voltage At Specific Temperatures
0° F
10 AMPS V
Alternator Voltage 14.0 V
Tractor Battery Voltage V
1.42 Volt 50 Amps
Ohms Resistance
Voltage Applied at Liftgate 10 Amps
° F

12. DUAL POLE CHARGING RATE
Battery Manufacture’s Suggested Charging Voltage At Specific Temperatures
0° F
30 AMPS V
Voltage Applied at Liftgate 30 Amps
Alternator Voltage 14.0 V
Tractor Battery Voltage V
1.42 Volt 50 Amps
Ohms Resistance
° F

13. FLOODED CELL BATTERY CHARGE ACCEPTANCE AT 0° F

14. 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

15. 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

16. 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.

17. FROM REEFER CHARGING SYSTEM DIAGRAM

18. TRAILCHARGER
The trailcharger is used to charge liftgate batteries at a regulated 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 0°F)

19. EXISTING TRAILCHARGER DIAGRAM
Connects to the tractor through the aux. pin which is key switched power

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

21. Perfect System Diagram
DUAL POLE CONNECTOR
SYSTEM BOX
TRAILCHARGER

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

23. 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.

24. OPERATION – ENGINE ON Aux pin is high
Magnetic switch closed, tractor batteries supplying current to the trailcharger

25. MATH EXAMPLES Liftgate Time up: 15 seconds Time down: 15 seconds
Total motor run time per lift: 30 seconds
30 seconds ÷ 1 hour = hours
Amps up and down: 200 amps
200 amps x hour = amp/hours
5 lifts per stop (1 hour), Six stops per day
5 x 6 = 30 lifts per day
30 lifts x amp/hours = amp/hours
Uses 50 amp/hours per day

26. 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

27. MATH EXAMPLES Total used per day: 140 amp/hours
Liftgate = 50 amp/hours
Lights = 90 amp hours

28. 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

29. 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

30. 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

31. 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 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

32. 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 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

33. TESTING DATA
MORE TEST DATA COMING