Industrial Forklift Batteries for Maximum-Power Applications

Triathlon Batteries is an ultramodern production facility for traction/motive power batteries. Triathlon primarily produces lead-acid batteries and lithium-ion battery systems for use in electric forklifts and pallet jacks, electric industrial trucks, mobile lifting platforms and other vehicles.

Triathlon’s technical expertise, experience with battery technology, and strong North American network located in Coppell, Texas guarantees competent consulting for our customers in every situation. Lift Truck Supply and Triathlon are also available and excited to help you transition from lead-acid to lithium-ion battery systems.

Lithium-Ion Batteries

TRIATHLON lithium-ion batteries have been developed and constructed for safe, reliable use in electric forklifts and pallet jacks. TRIATHLON battery systems are exclusively designed with high performance lithium-ion cells which fulfill all requirements for heavy duty industrial power use.

Tomorrow’s technology, already safe and cost-effective today!

This complete battery system consists of lithium-ion battery cells and modules, intelligent monitoring and control systems, extensive safety components, and a high-frequency opportunity/fast charger that communicates with the battery via CAN bus protocol.The battery system has active protection components which monitors the entire system and virtually eliminates any misuse.

As on option, TRIATHLON lithium-ion battery systems can be delivered with an externally wired and separately mounted multi-functional display that communicates battery discharge levels and other critical information.

Lithium-ion battery specifications:

  • Rated voltage: 24, 36, 48, 72, 80 volt
  • Available battery system energy content: 1.2 to 138.0 kWh
  • Available capacities: 52 to 1716 Ah
  • Discharging temperature range: -28° C to +55° C / -18° F to +131° F
  • Charging temperature range: -28° C to +55° C / -18° F to +131° F
  • Storage temperature range: -20° C to +45° C / -4° F to +113° F
  • Charge factor: 1.01 to 1.03
  • Voltage: 24 to 80 volt
  • Available charging power: 1.4 to 36 kWh
  • Available charging currents: 50 to 400 ampere
  • Efficiency: 95 to 97 %
  • No centralized charging station needed
  • Flexible – the TRIATHLON® battery system can be used and charged anywhere and at any time.
  • Fast Charge – full charging is possible within one hour.
  • Opportunity Charge – opportunity charging is possible and encouraged at any state of charge and will not reduce battery life.
  • Zero Emission – no gassing.
  • Efficiency – a high tech battery system combined with an extremely efficient high-frequency charger with easy to read display.
  • Capacity – the available energy is much greater than that of lead-acid batteries in the same box size. In most cases multi-shift use is possible without battery change-outs.
  • Performance – the higher sustained voltage priories of the TRIATHLON® Lithium-Ion battery result in faster more consistent lifting and driving performance, especially noticeable toward the end of the shift.
  • Energy Recuperation – the TRIATHLON® Lithium-Ion battery readily accepts any current fed back from the lift truck and uses it to increase run-time without any damage to the battery.
  • Safe – the TRIATHLON® battery system is equipped with deep discharge and overcharge protection, individual cell temperature and voltage monitoring and various other safeguards which will prevent a short-circuit.
  • Active – the TRIATHLON® battery system has active protection components which prevents application errors virtually 100% of the time.
  • TriCOM more – allows optional charging of up to eight batteries with only one charger.
  • TriCOM SR-Switching Technology – High system efficiency of up to 97 %.
  • More flexibility due to decentralized charging stations.
  • No explosion hazard and no odors due to gassing.
  • Longer operating times and higher productivity due to fast and opportunity charging.
  • The TRIATHLON® battery system is absolutely maintenance-free – it does not have to be topped off with water.
  • No need for battery change-outs and additional spare batteries.
  • No battery change-out equipment needed – the TRIATHLON® battery stays in the vehicle during charging and throughout its useful life.
  • No need for centralized battery rooms with expensive ventilation systems and fire doors.
  • Very low operating costs combined with significant savings in electricity and water costs.
  • TCO (Total Costs of Ownership) – significantly reduced total lifetime costs.
  • Virtually 100 % protection against application errors.
  • Significantly reduced CO2 footprint.
  • Different battery capacities and voltages can be charged on the same charger.

TRIATHLON® Lithium-Ion batteries can simply replace current lead-acid batteries without any modification to new or existing lift trucks. Custom designed trays with similar dimensions and weights and features make the conversion very straightforward: “LEAD OUT – LITHIUM IN”.

You begin from day one experiencing the cost savings and efficiency of TRIATHLON® Lithium-Ion technology.


Lead-Acid Batteries

TRIATHLON lead-acid batteries utilize the highly sophisticated tubular plate technology with flexible bolt-on inter-cell cable connectors. TRIATHLON tubular batteries are designed specifically for all power heavy duty applications and multi-shift operations. For light to medium applications we provide maintenance-free (valve-regulated) gel technology batteries that stand out for their excellent cycle life and ease of use.

TRIATHLON batteries and cells are built according to International Electrotechnical Commission Standards (IEC 60254-2).

TRIATHLON batteries of the T-US, TPzS, TPzB and TPzV product lines ensure safe and reliable power for electric lift trucks.

With our TA-US/TPzS AQUAsave battery lines, you can increase your productivity and lower your operating expenses through reduced watering intervals.

The TPzS Longlife line is designed to deliver longer service life that is realized by more charge/discharge cycles.

Lead-Acid Batteries:

Product features:

  • Width 6.20 in, US cell
  • Robust tubular flooded Lead-Acid technology
  • The latest separator design delivers increased acid volumes and increases acid circulation
  • Increased cycle life
  • Fully insulated flex connectors and post bolts
  • Bolt-on termination cables can be easily replaced
  • Standardized rated capacities range from 180 to 2000 Ah
  • Cell and battery properties comply with IEC 60254-2
  • Recyclable

Product features:

  • Width 6.20 in, US cell
  • Robust tubular flooded Lead-Acid technology
  • Low-maintenance Lead-Acid technology with low antimony content in the lead alloy and greater head space due to tubular design
  • Considerably reduced watering intervals (30 – 60 days) with optimized charge profile
  • The latest separator design delivers increased acid volumes and increases acid circulation
  • Increased cycle life
  • Fully insulated flex connectors and post bolts
  • Bolt-on termination cables can be easily replaced
  • Standardized rated capacities range from 180 to 2000 Ah
  • Cell and battery properties comply with IEC 60254-2
  • Recyclable

Product features:

  • Width 7.80 in, DIN cell
  • Robust tubular flooded Lead-Acid technology
  • Low-maintenance Lead-Acid technology with low antimony content in the lead alloy and greater head space due to tubular design
  • Considerably reduced watering intervals with optimized charge profile
  • Version A: 30 to 60 days
  • Version AX: 60 to 90 days
  • The latest separator design delivers increased acid volumes and increases acid circulation
  • Increased cycle life
  • Fully insulated flex connectors and post bolts
  • Bolt-on termination cables can be easily replaced
  • Standardized rated capacities range from 120 to 1550 Ah
  • Cell and battery properties comply with IEC 60254-2
  • Recyclable

Product features:

  • Width 7.80 in, DIN cell
  • Robust tubular flooded Lead-Acid technology
  • The latest separator design delivers increased acid volumes and increases acid circulation
  • Increased cycle life
  • Fully insulated flex connectors and post bolts
  • Bolt-on termination cables can be easily replaced
  • Standardized rated capacities range from 100 to 1550 Ah
  • Cell and battery properties comply with IEC 60254-2
  • Recyclable

Product features:

  • Width 7.80 in, DIN cell
  • Longer service life giving more charge/discharge cycles
  • Increased active material with reduced acid density
  • Robust tubular flooded Lead-Acid technology
  • The latest separator design delivers increased acid volumes and increases acid circulation
  • Fully insulated flex connectors and post bolts
  • Bolt-on termination cables can be easily replaced
  • Standardized rated capacities range from 110 to 1450 Ah
  • Cell and battery properties comply with IEC 60254-2
  • Recyclable

Product features:

  • Width 6.22 in, British Standard (BS) cell
  • Robust tubular flooded Lead-Acid technology
  • The latest separator design delivers increased acid volumes and increases acid circulation
  • Increased cycle life
  • Fully insulated flex connectors and post bolts
  • Bolt-on termination cables can be easily replaced
  • Standardized rated capacities range from 64 to 1080 Ah
  • Cell and battery properties comply with IEC 60254-2
  • Recyclable

Product features:

  • Width 7.80 in, DIN cell
  • Absolutely maintenance-free valve regulated Lead-Acid technology with gel electrolyte
  • Very low self-discharge
  • Tubular technology
  • The latest separator design delivers increased acid volumes and increases acid circulation
  • Fully insulated flex connectors and post bolts
  • Bolt-on termination cables can be easily replaced
  • Standardized rated capacities range from 110 to 1200 Ah
  • Cell and battery properties comply with IEC 60254-2
  • Recyclable

Product features:

  • Width 6.22 in, British Standard (BS) cell
  • Absolutely maintenance-free valve regulated Lead-Acid technology
  • Very low self-discharge
  • Tubular technology
  • The latest separator design delivers increased acid volumes and increases acid circulation
  • Fully insulated flex connectors and post bolts
  • Bolt-on termination cables can be easily replaced
  • Standardized rated capacities range from 122 to 680 Ah
  • Recyclable

Charging Technology

Innovative Charging Technology for Industrial Batteries

Optimal charging is critical to the performance of industrial batteries. The TriCOM range of chargers, which we exclusively distribute, guarantee you exactly that.

The most technologically advanced chargers for the best results. For this purpose the chargers operate with highly integrated circuit technology with timed power semiconductors. User-friendly, compact and robust housings ensure trouble-free operation and facilitate easy operation. The microprocessor controlled charging circuitry also monitors the charge process and ensures an optimal charge.

TriCOM FUTUR Charging Systems:

  • Maximum energy efficiency with a highest efficiency of up to 97 % realized through:
    • A pioneering multi-resonance converter technology “SR-Switching” for charging devices that is on-of-a- kind in the world.
    • An intelligent activation management system for the charging modules when operating under a partial load (3-phase chargers.)
    • Significantly reduced standby power consumption.
    • Optimal TriCOM FUTUR charge profile with IONIC Mixing.
  • “In-Service” Operation
    Chargers will continue to charge with reduced output even after the removal of individual modules.
  • Encapsulated cooling
    of the power semiconductors using heat sinks to keep dust and grime to a minimum.
  • Lead-Acid Batteries (tubular, flat plate, low-maintenance and maintenance-free)
  • Nickel Cadmium batteries
  • Lithium-Ion Batteries (optionally available with a CAN interface)
  • Programming of further battery types upon request.
  • SR-Switching HF (High Frequenz) charging system – High system efficiency of up to 97 %.
  • ECO Energy – Charging with the highest possible energy efficiency. Intelligent solution for wireless networking. Save resources using an easy-to-install battery monitor.
  • Graphik Touch Display – Intuitive operation via a 4.3″ multilingual touch screen with a real-time clock and time zone setting.
  • Plug & Play – Fully automatic with dynamic adjustments based on the battery’s age, temperature and state of charge.
  • Service Messages – Accurate display of all maintenance needs ans faults.
  • Total E-Control 4.0 – Wireless monitoring and management system permanently optimizes battery usage and the vehicle management system and thus saves resources.
  • Quick Check – Quick and easy inspection of the charger using ConVision, USB interface and the touch screen display.
  • Standard USB interface – For communication with data media: Update the firmware, read out the charge history, activate additional functions and control access to the charger settings.
  • Ease of Service – Modular design of the charger with an innovative plug-in technology and a cabinet concept that includes access from the side.
  • ConVision App – Concise programming and analysis system, stores the last 512 charge events in real time. Optimal analysis of your fleet, exact failure mode incident control. Provides ability to make battery/ charger decisions without additional effort.
  • Electric Standards – TriCOM FUTUR chargers comply with all European standards for EMC and electrical safety.
  • Options: Temperature sensor, Battery Management Counter, IONIC Mixing, Remote control – High flexibility, ideal for customization and makes economic sense.

Battery Management

Complete output control anytime, anywhere

Battery management systems are connected to the battery to check battery condition and to document operating conditions.

The patented technology used in TRIATHLON’s intelligent battery controller records not just the time and date, but also the number of charge and discharge cycles, electrolyte status, internal battery and ambient temperature, as well as total and half voltage. All of this ensures that you are always well informed about the condition of your batteries, and that there are never any unexpected failures.

icon Battery Guard 4.0 System:

  • Intelligent current measurement by using an easily mountable current measuring head
  • Wireless communication via Bluetooth
  • Storage of more than 4,000 discharge and charge data events with date, time and duration
  • Large status display with programmable status information
  • Customizable content display e.g. voltage, current, charge state, temperature, last charge fault information
  • Robust housing
  • Easy installation – no special tools required
  • Intelligent reporting
  • info Battery Guard software for individual programming of the controller and management of the data
  • Number of charges
  • Number of intermediate charges
  • Number and duration of low electrolyte level incidents
  • Number and duration of extreme (high or low) temperature incidents
  • Number and duration of deep discharges
  • Charge and discharge data
  • Extreme temperatures
  • Low electrolyte levels
  • Deep discharges
  • Amount of electricity (Ah) flow (in and out) during the respective charge/discharge cycles
  • Readout through the wireless interface with Bluetooth
  • Download data to a laptop/PC
  • Data transmission within the customer’s internal network

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