Forklift Batteries: The Guide

I need a forklift. I need it to lift this much and reach this height and be able to pick up this certain stuff. These are all questions most of you have considered that landed you here; reading drabble of an online forklift parts pusher. Well I have a question for you. Have you thought about how your forklift is going to be powered? Did you know you have a choice? Well I’m going to educate you on one of them. Batteries! Big ones.

In the forklift battery industry you have two choices either an old-school lead-acid battery or industry newbie Lithium Ion (Li Ion). Both have their own kinds of systems, setups, charging requirements, and price tags. While it looks like lead acids will be the industry leader through 2020 due to price and weight, within the next few years Lithium Ion will be as comparable in price and savings.

LEAD ACID BATTERIES

Lead acid forklift batteries have two main functions. They provide a power source and act as a counterweight to a lift truck. A typical lead acid battery is made up of a battery case, battery cells, and battery cables that come together to house a liquid electrolyte mixture of sulfuric acid and water.

How Lead Acid Batteries Work

lead acid battery diagram

Every battery cell houses layers of lead dioxide and spongy lead in alternating plates. When the charged acidic electrolyte mixture comes into contact with the plates; it creates an imbalance of electrons between the plates. Electrons will naturally travel from the negative spongy plate to the positive lead dioxide plate, attempting to correct the imbalance. This addition of electrons changes the lead dioxide in the positive plate into lead sulfate; this reaction is what creates the electrical charge that flows through the terminals and into your lift. This process is called discharging.

*When discharging small amounts of oxygen and hydrogen gas byproduct are created as the electrolyte mixture evaporates from the heat produced by the chemical reaction. The byproduct is freely released out of the vented cap on the cell. Keep reading to learn about how to replace this water loss.

Forklift battery chargers force a reverse process.

There are two different types of lead acid batteries to choose from: Solid Plate and Tubular:

The Difference Between Solid Plate And Tubular Plate Lead-Acid Batteries

There is only one major design difference in Solid vs Tubular and it is all about the Positive Plate. The negative plates in all Lead-Acid Batteries are Flat Pasted Plates.

  • Solid Plates are flat, positive plates made by pasting lead oxide active mass onto a mesh grid. Fast Charging (maintains the battery between 20 & 80% charge by charging on scheduled breaks) is not possible and must be charged fully without interruption. Requires a weekly equalization charge.
  • Tubular Plates use a frame containing vertical spines connected to a common bus bar. The tubular design keeps the active material together and presses it onto the grid. The paste is held in micro-porous, non-conductive tubes which are placed over the spines. Combining the spines, gauntlets, lead oxide, and bottom bar together makes a positive plate. With tubular plates you are able to Opportunity and Fast Charge your Battery. Each week you must provide the battery with a finish and equalization charge.
Tubular BatteriesFlat Plate Batteries
Life expectancy 4 to 5 yearsMaximum 3 years
Low water lossNeeds frequent water topping up
Cyclic Life is HighLow cyclic life
Operate consistently even at high temperatures.Useful only at recommended temperature conditions.
Complex design.Simple design.
High Price.Affordable price.
Fast charging battery.Charges slowly compared to tubular batteries.
Recommended for high productive applications.Recommended for small homes and budget-conscious people.
Highly reliableReliable

Chargers

Industrial chargers are needed to charge your battery. They charge your battery as quickly as possible without decreasing the battery’s lifespan. They also monitor your battery for overheating and over charging. These chargers allow you to set your charging cycle to control the voltage, charging times, amps, and fill rates giving you extended battery life. Some chargers are on wheels and are moved from lift to lift and others are fixed fixtures where the battery is driven or hoisted to its station.

Charging a battery whenever it is convenient is not the best way to go, it should only be charged at certain times and to certain degrees. You should charge a forklift’s battery only when it dips below 30% to preserve your plates. Over or undercharging industrial batteries can significantly decrease its overall lifespan. Choosing the right charger for your battery will significantly help lengthen the return on your investment.

COMPLETE BATTERY PPE KIT
The self-contained kit comes with: neoprene safety gloves, safety goggles, face shield, apron, flashlight, battery cap removal tool, and hydrometer.
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Electricity For Chargers

When installing battery chargers you need to take your phases into account. Many manufacturers offer either single or three phase chargers. You should take into account on how your building is wired when purchasing a charger to avoid rewiring and to get the best charge while avoiding damage to your system or battery.

  • Single Phase is a two wire alternating current power circuit. It is commonly used in homes or small business to power lighter items such as TVs and lights. Usually there is one power wire and one neutral wire; power flows between the power wire through the load and the neutral wire.
  • Three Phase is a three wire alternating current power circuit. It is commonly used in commercial buildings for large HVAC systems, larger water heaters, and for industrial equipment. 3 Phase 4 Wire power arrangements are used because of its power density. A 3 phase power arrangement provides 1.732 times more power than a single phase.
    • The advantage of three phase charger is that they will draw less amps for charging.
    • Reduced construction costs because a smaller electrical service, wiring, conduits, and electrical devices are needed to achieve the end goal.
    • Reduced energy costs as less energy is lost as electrical current resistance.

Parts Of A Typical Charging Station

  1. Charger case
  2. Circuit cards
  3. Capacitors
  4. Transformers
  5. Digital display
  6. Charger cable
  7. Gauge cables
WALL MOUNTED CHARGER BRACKETS
Reduces floor damage of chargers and allows for a clean and safe floor area (universal fit). Dimensions: 24.13″ deep x 24.13″ tall. Supports up to 400 lbs. on a wall with sufficient bearing strength.
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Battery Monitoring

Battery monitoring systems can cover voltage spikes or drops, amp hours, water levels, etc. These systems consist of either or both a plain monitor and a battery water monitor. These are important because batteries need to be charged and watered proportionately to extend its life.

Watering and Water Monitoring

Your lead acid battery contains a liquid electrolyte mixture of sulfuric acid and water. Small amounts of oxygen and hydrogen gas that are created during discharge gets released out of the vented cap on the cell.  Evaporation. Got to love it but, you have to have to replace the lost moisture or risk burn out. An industrial battery can last up to the manufacture’s specifications if properly watered and maintained. To help get this accomplished proper watering is a must.

There are several ways to water a battery. Some are more convenient than others. What matters is that each cell in each battery is only watered until reaching the top of the lead acid plates. These plates are visible in each cell and are usually about 2.5 inches below the cell cap. If you over water your battery it to can lead to several serious issues like cauliflowering, leaks, worker injury, and battery failure.

Only top off a battery after the battery is fully charged. It is also important to use the right water, which measures between 5 and 7 on the pH scale and is within recommended limits for impurities. Impure water can lead to battery damage.

Watering Systems

  • Gravity Feed System – This system features a large water drum or tank hoisted in the air and has a hose attached to it that the operator takes from cell to cell until they are properly filled.
  • Battery Watering System – These systems hook your batteries up to a hose that attaches to each cell, and properly fills each cell. After which, it automatically shuts off when each cell is properly filled.
  • Watering Gun Method – This method involves hooking a battery watering gun attachment to a hose and going cell-by-cell and manually filling each cell to the proper levels.

If you do not maintain the battery you can lose a significant amount on your investment by cutting the life of the battery in half or even thirds. If batteries are not properly watered; downtime and maintenance increase while battery lifespan and safety decrease.

Protect your investment by ensuring your staff know how, when, and where to water your batteries.  Proper handling and procedures are paramount to extending the life of your equipment and providing safe working conditions to your employees.

BATTERY CARE BOX
Proper battery care for forklift batteries requires special tools and personal protection equipment in order to do the job right.
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Keep Batteries At A Safe Temperature

Forklifts can be used in pretty extreme environments, so you have to consider the temperature of the batter when in use. Keeping a battery at a safe temperature and not exceeding 113℉, will help to prolong its life. Be sure there is plenty of air circulating in and around the battery compartment for optimal cooling.

Hazards

  • Generates heat
  • Produces harmful Gas
  • Can splash acid
  • Battery cables fraying
BATTERY ACID SPILL KIT
Proper battery care for forklift batteries requires special tools and personal protection equipment in order to do the job right.
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Lead Acid Cost And Buying Questions

Lead Acid Battery prices depend on brand, size, ect. Lead Acid Batteries typically weigh from 800 pounds to as much as 4,000 pounds. Before you purchase consider the following:

  1. What is the vehicle voltage or number of cells in the battery?
  2. Does the truck require an EE (Spark Proof – for use in a mildly hazardous areas and has any sparking parts enclosed) or EX battery (Explosion Resistant – for use in highly hazardous areas and has extra spark protection)?
  3. What is the compartment size of the truck?
  4. Is the truck compartment covered or does the battery require a cover?
  5. What kind of charging connector?
  6. What position on the battery do you wish the battery cables to come off the tray?
  7. Do I need a charger and how many?
  8. What type of power do I need – three phase or single phase?

LITHIUM ION BATTERIES:

How Lithium Ion Batteries Work

Lithium Ion batteries are made up of an anode, cathode, separator, electrolyte, and positive and negative terminals. The anode and cathode house the lithium. The electrolyte carries positively charged lithium ions from the anode to the cathode and then back again through the separator. The movement of the lithium ions creates free electrons in the anode which creates a charge at the positive terminal.  The electrical current then flows from the positive terminal through the lift to the negative terminal. The separator blocks the flow of electrons inside the battery.

lithium-ion-batteries

When the battery is discharging and it provides an electric current, the anode releases lithium ions to the cathode, creating a flow of electrons from one side to the other. When plugging in the battery to charge, the exact opposite happens: Lithium ions are released by the cathode and received by the anode charging the battery.

Advantages:

  • Long cycle and extend shelf-life
  • Maintenance Free
  • High energy capacity
  • Short charge times
  • Low self-discharge
  • Worker and Environmental Safety, no hydrogen fumes or acid splash hazards
  • Less time and labor expended by workers swapping out lead acid batteries or maintain them

Disadvantages:

  • Requires a circuit to prevent thermal runaway if stressed
  • Degrades at high temps and when stored fully charged
  • Initial cost
  • Requires additional counter weight in battery compartment

Charging

Li Ion batteries have a NO MEMORY EFFECT; you do not have to completely or partially discharge the battery before recharging and it can handle hundreds of charge/discharge cycles. This is perfect for Fast or Opportunity Charging during worker breaks or between shifts allowing you to purchase fewer batteries and lose less work hours in removal and replacement of lead acid batteries.

Electricity For Chargers

When installing battery chargers you need to take your phases into account. Many manufacturers offer either single or three phase chargers. You should take into account on how your building is wired when purchasing your charger to avoid rewiring and to get the most out of your charge while avoiding damage to your system or battery.

  • Single Phase is a two wire alternating current power circuit. It is commonly used in homes or small business to power lighter items such as TVs and lights. Usually there is one power wire and one neutral wire; power flows between the power wire through the load and the neutral wire.
  • Three Phase is a three wire alternating current power circuit. It is commonly used in commercial buildings for large HVAC systems, larger water heaters, and for industrial equipment. 3 Phase 4 Wire power arrangements are used because of its power density. A 3 phase power arrangement provides 1.732 times more power than a single phase.
    • The advantage of three phase charger is that they will draw less amps for charging.
    • Reduced construction costs because a smaller electrical service, wiring, conduits, and electrical devices are needed to achieve the end goal.
    • Reduced energy costs as less energy is lost as electrical current resistance.

Battery Monitoring

Battery monitoring is a must for lithium ion batteries. Without the system you are susceptible to overcharging.

Most monitoring systems offer the following:

  • Protects the battery pack from being over-charged
  • Calculates charge
  • It monitors the health and safety of the battery pack by constantly checking for shorts, loose connections, and defective cells
  • Bleeds off excess energy
  • Monitors the temperature
  • Relays real-time information
  • Stores error and diagnostic info

Lithium Ion Cost And Buying Questions

Lithium ion batteries cost vary up to $45,000 depending on the size, voltage, counterweight needed, etc. Before you purchase consider the following:

  1. What is the vehicle voltage needed?
  2. What is the compartment size of the truck?
  3. What counterbalance weight is needed?
  4. Is the truck compartment covered or does the battery require a cover?
  5. What kind of charging connector is used on the truck?
  6. What position on the battery do you wish the battery cables to come off the tray?
  7. What type of power do I need at my facility to charge the batteries – three phase or single phase, voltage?

With two great choices you can see how many battery debates start. It all comes down to you, your application, and your preference between old and new technology. With new strides in the battery industry either choice could be right for you. Check with your local forklift dealer to see all options available to your fleet.[space]

For more information about forklift batteries and how they can be an asset to your business:

Contact Lift Truck Supply
T:1.800.873.1828
E: marketing@short-pear.flywheelsites.com
F: Contact Page


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