GYS helps CV fleets cut battery replacement costs
For commercial vehicle operators, maintaining reliable battery performance is essential to keeping vehicles on the road and reducing unexpected maintenance costs, says charging equipment specialist GYS. But the company warns that one frequently overlooked issue in 24V electrical systems is battery imbalance, which can lead to premature battery failure and unnecessary replacement expenses.
“As is widely known, most conventional HGVs and buses operate with two 12V batteries connected in series to provide a 24V electrical supply,” said GYS.
“Over time, differences in their individual states of charge can develop, affecting the performance and reliability of the battery pack.
“Battery imbalance occurs when the two batteries no longer maintain equal states of charge. This can arise from several factors, including differences in internal resistance caused by manufacturing variations or uneven ageing. Temperature fluctuations, varying electrical loads and inconsistent maintenance practices can also contribute to the imbalance.
“When the batteries are charged together through the vehicle’s 24V electrical system, these differences are not necessarily corrected. As a result, one battery may remain undercharged while the other reaches a higher state of charge.
“The overall performance of the battery pack can then become limited by the weaker battery, potentially reducing its service life and increasing the likelihood of starting difficulties. For fleet operators, this can mean more frequent battery replacements, unexpected vehicle downtime and additional maintenance costs.”
To help avoid this, GYS offers a dedicated battery balancing solution designed for commercial vehicles operating with 24V battery systems.
The system consists of two connected GYSFlash battery support units working alongside a Smart Hub Module, allowing each 12V battery to be charged independently and brought to an equal state of charge.
The system can balance the two batteries in as little as two hours, says GYS, while its connected technology also enables software updates and customised charging configurations to suit different battery requirements.
“This provides a practical addition to routine commercial vehicle maintenance, allowing the balancing process to take place while other servicing work is being completed.”
