Maxim Khabur

Maxim Khabur

For more information, please visit Lithium Storage.

How to choose the right Forklift Battery

OneCharge

Aston
Irvine, CA
http://onecharge.biz/

Choosing industrial batteries can be complicated&#;there are just so many options that it can be difficult to decide which factors are most important: Ah capacity, chemistry, charging speed, cycle life, brand, price, etc.

If you already know what to expect of your battery, use the forklift battery selector to see available options.

If you&#;d like to learn which requirements of your material handling operations are crucial for choosing the right forklift battery, read on.

1. Start with the make and model of your forklifts and lift truck specs

Your choice of power source for the equipment is defined primarily by the forklift&#;s technical specifications. As the users of diesel- or propane-powered Class 4 and 5 sit-down forklifts continue to convert to Class 1 electric, more than half of lift trucks today are battery-powered. Durable, high-capacity Li-ion batteries have become available for even the most demanding applications handling heavy and bulky loads like steel, lumber, paper, and beverages.

The following are the main specs you need to look at.

1.1 Battery voltage (V) and capacity (Ah)

There are several standard voltage options (12V, 24V, 36V, 48V, 72V, 80V) and different capacity options (from 100Ah to Ah and higher) available for various lift truck models.

For example, a 24V 210Ah battery is typically used in 4,000-pound pallet jacks, and 80V Ah would fit a counterbalanced sit-down forklift to handle loads up to 20K pounds.

1.2 Battery compartment size

The dimensions of a forklift&#;s battery compartment are often unique, so it is crucial to find a perfect and precise fit. It is also important to consider the cable connector type and its location on the battery and a truck.

Some OEM manufacturers (e.g. Combilift, AisleMaster) have two battery compartments of different sizes. The CUSTOM Series lithium battery is a good example of how a battery is engineered to meet certain equipment&#;s unique specs.

1.3 Battery weight and counterweight

Different forklift models have different recommended battery weight requirements that you should consider while making your choice. An additional counterweight is added to a battery intended for use in applications with heavy loads.

1.4 Li-ion vs. lead-acid forklift batteries in different types of electric forklifts (Classes I, II, and III)

Lithium batteries are best suited for Class I, II, and III forklifts and other off-road electric vehicles, like sweepers and scrubbers, tugs, golf carts, etc. The reasons? Triple the lifespan of lead-acid technology, excellent safety, minimal maintenance, stable operation at low or high temperatures, and high energy capacity in kWh.

LFP (Lithium Iron Phosphate) and NMC (Lithium-Manganese-Cobalt-Oxide) batteries are both used in electric forklifts. The recent tests of lithium battery types at Sandia Laboratories show that LFP batteries will actually last longer and are more reliable than NMC.

NMC and NCA (Lithium-Cobalt-Nickel-Oxide) types of lithium batteries are more commonly used in passenger EVs and electronics due to their lower overall weight and higher energy density per kilogram. NMC industrial batteries are used by some OEM manufacturers (Kalmar, for example) in construction equipment like cranes and excavators.

Until recently, lead-acid batteries have been widely used in all types of electric forklift trucks. TPPL is the newer version of such batteries. It has higher efficiency and higher charging speed but only compared to traditional flooded lead-acid technology or sealed lead-acid batteries, like absorbent glass mat (AGM).

In most cases, lithium-ion batteries are a much more economical and efficient choice for industrial applications than any lead-acid battery, including AGM or TPPL batteries.

1.5 Forklift-battery communication

A Controller Area Network (CAN bus) allows microcontrollers and devices to communicate with each other&#;s applications without a host computer. Not all battery brands are fully integrated with all forklift models through the CAN bus. Then there is the option of using an external Battery Discharge Indicator (BDI), which provides the operator with visual and audio signals of the battery&#;s state of charge and readiness to work.

At OneCharge, we make both options and are ready to develop CAN options with any lift truck make and model.

2. Factor in the details of your material handling equipment application and your company policies

The battery&#;s performance must fit the actual use of the forklift or lift truck. Sometimes the same trucks are used in different ways (handling different loads, for example) in the same facility. In this case, you may need different batteries for them. Your corporate policies and standards may also be in play.

2.1 Load weight, lift height, and travel distance

The heavier the load, the higher the lift, and the longer the route, the more battery capacity you will require to last the whole day. Take into consideration the average and maximum weight of the load, travel distance, height of the lift, and ramps. The most demanding applications, such as paper and packaging or food and beverage, where load weight can reach 15&#;20 thousand pounds, will require an 80V POWER Series lithium battery with up to Ah capacity.

2.2 Forklift attachments

As with the load weight, the size of the pallet, or the shape of the load that needs to be moved, using heavy forklift attachments will require more &#;gas in the tank&#;&#;higher battery capacity. A hydraulic paper clamp is a good example of an attachment for which you need to plan some extra power.

2.3 Freezer or cooler

Will a forklift operate in a cooler or freezer? For low-temperature operations, you&#;ll probably need to choose a forklift battery equipped with additional insulation and heating elements, like the FROST Series lithium battery.

2.4 Charging schedule and speed: LFP and NMC Li-ion vs lead-acid battery

Single battery operation eliminates the need to replace a dead battery with a fresh one during the workday. In most cases, this is only possible with the opportunity charging of a Li-ion battery during breaks, when it is convenient for the operator and does not disrupt the production process. Several 15-minute breaks during the day are enough to keep the lithium battery at over 40% charge. This is a recommended charging mode that provides top performance for a forklift and helps to extend the useful life of the battery.

Read the full text of How to Choose the Right Lithium Forklift Battery.

2.5 Data for fleet management needs

Fleet management data is primarily used to track maintenance, improve safety compliance, and maximize equipment utilization. Battery management system (BMS) data can significantly enrich or replace data from other sources with detailed info on power consumption, the timing of charging and idle events, battery technical parameters, etc.

Easy data access and the user interface are becoming the most important factors when choosing a battery.

2.6 Corporate safety and sustainable development standards

Li-ion batteries are the safest option for industrial forklifts. They don&#;t have any of the issues of lead-acid technology, such as corrosion and sulfating, and do not emit any pollutants. They eliminate the risk of accidents associated with the daily replacement of heavy batteries. This benefit is crucial in industries such as food and beverage, medical supplies, electronics, etc. With Li-ion electric forklift batteries, you do not need a specially ventilated room for charging.

Read the full text of How to Choose the Right Lithium Forklift Battery.

3. Evaluate the battery price and future maintenance costs

3.1 Maintenance

A Li-ion battery does not require daily maintenance. Lead-acid batteries need to be watered, cleaned after occasional acid spills, and equalized (applying special charging mode to equalize cells charge) regularly. Labor and external service costs tend to increase as the lead-acid power units age, resulting in decreasing uptime and contributing to constantly increasing operational costs.

Read the full text of How to Choose the Right Lithium Forklift Battery.

3.2 Battery acquisition price vs total cost of ownership

The purchase price of a lead-acid power unit plus charger is lower than a lithium package. However, when switching to lithium you need to take into account the increase in uptime provided by single battery operation and the flexible opportunity charging schedule, the 3-fold increase in the battery&#;s useful life, and lower maintenance costs.

Calculations clearly demonstrate that a lithium-ion battery saves up to 40% in 2&#;4 years on the total cost of ownership compared to a lead-acid battery.

Among lithium batteries, the LFP lithium battery type is a more economical and efficient choice than NMC lithium batteries.

In most cases, it makes economic sense to switch to Li-ion, even if you operate a small fleet or a single forklift.

3.3 How often do you buy new batteries for your forklifts?

Lithium batteries have a longer lifespan than any lead-acid power pack. Lead-acid batteries lifespan is &#; cycles or less. Lithium-ion lasts at least 3,000 plus cycles depending on the application.

TPPL lead-acid batteries have a longer lifespan than conventional liquid-filled or sealed AGM batteries, but they can&#;t even come close to a lithium-ion technology in this aspect.

Within lithium, LFP batteries demonstrate a longer cycle life than NMC.

3.4 Battery chargers

Compact Li-ion forklift battery chargers can be conveniently located around the facility for opportunity charging during breaks and lunches.

Lead-acid batteries require massive charging stations and need to be charged in a ventilated charging room to avoid risks of contamination associated with acid spills and fumes during charging. Eliminating a dedicated battery room and bringing back this space to profitable use usually make a big difference for the bottom line.

Read the full text of How to Choose the Right Lithium Forklift Battery.

4. How to choose a battery with a focus on brand and vendor

4.1 Consultative selling

Selecting and procuring the right battery can take a lot of effort and time. Your supplier will need to provide professional information on what battery set-up is optimal, and what the trade-offs and must-haves are for your specific equipment and operation.

4.2 Lead time and accuracy of shipments

A plug-n-play solution is more than just easy installation and set-up. It includes due diligence in battery configuration for a specific task and application, connection protocols like CAN bus integration, safety features, etc.

So, on the one hand, you&#;d want to have the batteries delivered just in time when your new or existing forklifts are ready to start. On the other hand, if you choose just what is available and rush the order, you may discover that a lift truck or your material handling operations are incompatible with the batteries.

4.3 Support and service in your location and past customer experience

The availability of forklift battery support and service in your area affects how quickly you resolve your equipment issues.

Is your vendor ready to do everything possible in the first 24 hours to make sure your equipment works, no matter what? Ask former customers and OEM dealers for their recommendations and past experience with the battery brand you plan to purchase.

4.4 Product quality

Product quality is mainly defined by how closely a battery can meet the requirements of operations. The right capacity, cables, charging speed set-up, protection from weather and from incorrect treatment by inexperienced forklift operators, etc.&#; all these determine the quality of battery performance in the field, not the numbers and images from a spec sheet.

About the Author:

Maxim Khabur is the Marketing Director of OneCharge, Inc., based in Irvine, CA.

Today, forklifts usually use a forklift battery to supply their motive power, because it is environmentally friendly.  Also, they can avoid dangerous fumes, such as carbon monoxide. Choosing the proper ones keeps your forklift in production during every shift. Also, charging properly makes a long life for your battery. 

However, many laypeople don&#;t realize how easy it is to make severe mistakes when dealing with a forklift battery. Luckily, the following information will be beneficial to you.

1. Forklift Battery Types

Here are three forklift battery types people use the most. Each one depends on the forklift&#;s use.

(Render of an industrial forklift)

Lead-Acid

Operators use these forklift batteries the most, as they are easy to use. They are liquid-filled wet cell batteries in a big shape with a removable top. Through the chemical reaction of lead plates and sulfuric acid, it generates electricity. 

Also, with the right maintenance, they last over 5 years. Every battery manufacturer recommends users do regular maintenance. This ensures accurate battery voltage and electrolyte levels to grant top battery performance.

Lithium-Ion

Although expensive, lithium-ion batteries have a long list of benefits in comparison to others.  For example, one of the most popular chemistries they have is Lithium Iron Phosphate (LFP),  which is more energy-dense than lead-acid.   Instead of a removable top, the cells are sealed shut. Even there is no water maintenance, they can work properly.

(Rechargeable electric forklift)

Absorbed Glass Mat (AGM) Forklift Batteries

Although this type of battery is not as common as lead-acid or lithium-ion batteries, AGM batteries benefit a lot. The glass mat inside the battery passes electrolytes between plates. By suspending electrolytes in this dry state, maintenance requirements decrease. This avoids any accidental acid spillage in case of a cracked battery case. 

(Forklift battery ready for replacement)

On the downside, their performance lowers when charged improperly. Manufacturers recommend discharging the battery to no less than 50% on each use to ensure top performance.

Are you interested in learning more about 48 volt forklift battery for sale? Contact us today to secure an expert consultation!

2. Forklift Battery Price

Buying a forklift battery is an investment. When considering battery prices, you should consider the initial buyout price and the maintenance costs over a certain period. This makes the lithium-ion battery a better option.

Lead-acid batteries last about 5 hours with one single charge. However, it needs up to 8 hours to fully charge and an extra 8 hours to cool down. With proper maintenance, these will last up to charging cycles.

(Several forklifts parked inline)

On the other hand, lithium-ion batteries last over 7 hours with a single-use. They only need up to 2 hours to charge completely and need no cool-down. In addition, with proper maintenance, lithium-ion batteries last up to cycles.

Lithium-ion forklift batteries are almost double the price of lead-acid ones. However, over the course of 5 years of use, using lithium-ion ones grants you savings of over $20K per battery. Just think of the big picture here, the more lithium-ion forklift batteries you own, the more savings you&#;ll have.

(Man in forklift)

3. Forklift Battery Sizes

Whether they are big or small, light or heavy, forklift battery sizes vary depending on the vehicle they will supply the power to. 

24-volt forklift battery

It is perfect for anything small like electric walkie pallet jacks, end riders, walkie stackers, or center riders.

36-volt forklift battery

When it comes to narrow aisle forklifts or any other mid-sized vehicle, a 36-volt battery is a way to go. 

(Industrial battery)

48-volt forklift battery

If you work with counterbalanced electric forklifts or any other large electric lifting vehicle, a 48-volt battery will do the trick.

80-volt forklift battery

They work with any extra-large, heavy-duty vehicle.

4. Forklift Battery&#;s Common Risks

As forklift batteries are bigger than regular car or truck batteries, the risks and consequences increase exponentially. However, lead-acid batteries present the most common risks.

(Battery spilling warning signal)

Dangerous Gases

Lead-acid industrial batteries emit dangerous gases when overcharged. This includes hydrogen, hydrogen sulfide, and sulfur dioxide. It&#;s important to ventilate the charging room at all times. Or at least,  install sensors to measure the concentration to avoid explosion.

Overheating

While charging, a lead-acid forklift battery raises its temperature after peaking charge for too long. It&#;s crucial to control the temperature of the charging station, the room, and the battery itself to prevent accidents.

(Rechargeable forklift battery with the electric connector on top)

Spills

Battery acid causes chemical burns, hindering workers&#; overall job performance. The same thing happens when it comes to slips and falls. Lead-acid batteries need weekly watering. For this, it is recommended to have a chemical washing station on the premises to deal with battery acid spillage and burns. 

Old, Corroded Batteries

A new lead-acid forklift battery presents no safety hazard to operators. On the contrary, an old and corroded battery multiplies the risks.

(Corrosion on battery cables)

Other risks of using any of these forklift batteries include physical injuries to workers. This includes lifting battery weight, moving, charging the batteries, and injuries if a battery falls on anyone. 

5. Forklift Battery Watering System 

As mentioned above, lead-acid batteries need constant, regular, and much-needed watering to function the right way while lithium-ion ones need no watering at all. 

(Operator checking water levels on forklift battery)

To make it work, it&#;s crucial to only water the battery once it&#;s charged and completely cooled down. Also, be extremely cautious not to overfill it to avoid spillage. Leave space inside for the fluids to expand and use water that&#;s level 5 to 7pH in the acidity scale. In addition, it&#;s vital to water the forklift batteries every 9 or 10 charging cycles to avoid the exposition of the lead plates&#; tops.

6. Forklift Battery Charging

Proper battery charging leads to extended battery life. Whether for lead-acid or lithium-ion, there are some factors you should consider before starting the charging cycle on your forklift battery.

(Forklift batteries on charging station)

Charging Time

While lead-acid batteries take 8 hours to charge up to 100%, lithium-ion ones take only 1 to 2 hours per charge cycle to do so.

Cool-Down Time

When it comes to cool-down time, lithium-ion batteries take the lead by far. Lead-acid batteries have to cool down for another 8 hours before using them. Lithium-ion forklift batteries don&#;t need cool-down time. They can be opportunity-charged and don&#;t need to be fully charged to use it.

Charging Method

The charging method is very different. Lead-acid batteries need to charge in a separate charging room where they remain until hitting 100%.On the other hand,  lithium-ion batteries charge by plugging the cord directly into the wall without removing it from the vehicle.

(Forklift batteries charging on charging station)

7. Forklift Battery Maintenance

Electric forklift batteries maintenance is easier than your think. Yet, it should be regular, consistent, and thoroughly done. There are some major tips to follow.

Check Water Levels

Check the electrolyte level every 5 to 10 charging cycles, and only once the battery is completely cool. In addition, be aware of white crystal formation on the plates. If this occurs, it&#;s time to call an experienced engineer to solve the issue.

Clean Batteries Regularly

Clean the top of the battery with warm water or battery cleaner to avoid corrosion.

(Battery operator handling a battery while using protective gear)

Use Protective Gear

Use protective gear when handling the battery. This includes face shields, protection glasses, and steel-toe shoes, among others. Also, remove the jewelry and all metallic accessories while handling battery acid.

8. Signs of Forklift Battery Repair or Replace

Some signs let users know when or if their forklift battery needs repair or replacement.e signs that let users know when or if their forklift batteries need repair or replacement. 

Sulfation or Corrosion

Corrosion appears as a sign of battery age, and sulfation shows due to over-or undercharging. But no matter what happens, it&#;s best to replace it.

(Sulfated forklift battery)

Constant Charging

Constant charging translates to constant stopping while working, wasting your time and money overall.

Smoke while Using or Charging

If the battery releases smoke while charging or using, it means gasses inside our building and is an explosion hazard. 

Odd or Rotten Smell while Using

If an odd or rotten egg smell is present while using the forklift, it means the battery has corrosion inside it. 

(Disgusted man covering his nose)

Conclusion

Knowing how to choose the correct battery cell for your business&#; needs can make or break your entire business plan. Hopefully, you now know how to do it right. If you are looking for any type of battery cable assembly for your forklift, contact us.

If you are looking for more details, kindly visit lithium iron phosphate battery disadvantages.