Smart / Regenerative Split Charging Problem and Solution
With most later Euro 5 / Euro 6 commercial vehicle charging systems being of smart regenerative braking we had to find the solution for auxiliary battery charging. The earlier type of intelligent split charge relays are no longer an option. We have found split charging issues on Mercedes Blue Efficiency Sprinters, VW T5 and T6 Blue motion and Fords Econetic Transits. We are commonly ask as to why my split charging doesn’t work on these later vehicles and it is because the older constant charge voltage of around 13.8v no longer happens. Part of the strategy for these vehicles to become more efficient is by using waste energy that is usually in the form of heat in your brakes by getting the alternator to produce a high charge rate on deceleration. During acceleration and cruising the vehicle then consumes this “Free “electrical energy which in turn reduces alternator load on the engine, increasing mpg and reducing CO2.
The problem when trying to charge auxiliary batteries with the smart alternator / regenerative systems when using a voltage sensitive relay, is the voltage swings .Trouble happens when the auxiliary is not getting any serious charging when low on voltage and then getting damaged by the high voltage and large circuit current rushes. The end result is premature destruction of the batteries especially sealed Gel and AGM types.
The solution is our Dc-Dc battery charger which in effect increases the voltage to the auxiliary when the smart system is in low voltage mode and reduces the voltage when high. It also stops any large rush surge of power coming through so keeping the charge cycle constant. The Dc-Dc charger also can increase the voltage to accommodate longer cable runs thus compensating voltage drop. This results in up to 10 times faster charge rates.
Please see the Range of DC-DC chargers in our store.
lisa basham December 22nd, 2015
Posted In: Miscellaneous