An onboard charging system converts alternating current from an external source to a direct current. It then supplies this Direct current to a forklift battery pack. The onboard battery charger has a built-in battery management system (BMS). It uses this management system to charge the battery. It also makes sure that charge rate and protection are appropriate.
Figure 1. A forklift onboard battery charger
The Forklift Charger is a compact device. Its technology has all the elements that a portable charger contains. It is equipped with safety features. It can protect the battery from reverse current. It can disconnect controlled load automatically. It can recharge all the forklift batteries such as the following:
conventional forklifts (one charger per lead)
powered platforms (one charger per battery bank)
hybrid vehicles (one charger per bank)
Summary
The following information helps the readers to select the suitable onboard battery charger for their forklifts. It also informs them of the correct method of use of forklift battery charger.
Make sure that the truck's key switch is turned off.
Choose a charger that displays the message "Connect a battery" on the screen
Raise the seat, detach the battery from the fork hoist, and reconnect it to the charger.
After connecting the battery to the charger, the auto countdown will begin.
Verify the status of the green light to ensure that charging is occurring.
After charging the truck's battery, unhook the connections and press the Stop button
Make sure that the screen says "Reconnect battery" after disconnecting the wires.
Then disconnect the charger while removing all charging wires from the forklift.
Finally, reconnect the battery wires and lower the seat and hood.
Optimum Battery charge levels for the usage of onboard batteries
It is advisable to get the vehicle battery recharged when the charge falls below 20%. If the charge level goes below 20%, the battery life may shorten. Thus, the ideal time to use a battery charger is when the remaining charge level is between 20% and 30%. You should remove the charger only after the total charge. This way, it ensures battery life and performance.
Application of an onboard battery charger for various forklift battery types
Always keep in mind the battery type for which you wish to purchase a charger. Trucks typically have lead-acid batteries. Sometimes, these are referred to as wet cell batteries. They are composed of a casing, cells, cables, and a sulfuric acid solution. They require routine maintenance to ensure optimal function. The onboard battery charger must operate at a constant current and voltage. In this way, the batteries are charged accurately,
There is an alternative to lead-acid batteries: An absorbent glass mat (AGM). They have a unique glass mat. Between plates, it acts as a barrier. They are maintenance-free batteries. They last longer when discharged at a rate of up to 50% in each cycle.
Lithium-ion batteries are also becoming increasingly common. They offer the most in comparison to other types of batteries. They are maintenance-free and require no water. They pose no risk of overcharging.
How to choose the correct forklift battery charger
If the incorrect combination of forklift components is used, you risk the battery life to low performance. You may then be required to change the battery as well. In this way, your bear the cost to replace the battery.
If you are the owner of a facility, then you should think about selecting the appropriate battery and charger combination. It would help if you addressed the following questions in this case.
What is the voltage level of your batteries? Is it 24, 36, 48, 80V, or something else?
How many shifts are you currently operating?
For how many hours does your forklift operate? And in how many shifts?
How many times do you fill up again your batteries with water?
How many hours do batteries take to cool after being charged?
By addressing these questions, it becomes easy to select the right combination. The right combination enhances the performance of the battery.
Factors to consider when selecting a compatible charger for a truck battery
It is essential to pick a charger that is compatible with your vehicle battery. It is essential for the long life of your truck battery.
Always choose a charger that is suitable with your truck's Ampere hour (Ah) rating. Incompatible chargers can cause lead sulfates to accumulate.
When selecting a battery charger, keep in mind the size of the battery that your forklift utilizes. The charger system should be proportional to the size of the battery. The well-suited charger contributes to performance. As a general rule, your battery charger should be at least 10% of the battery's Ah rating. For example, a charger for a 200Ah battery should be at least 20 Amps.
When choosing one for your truck battery, always keep in mind the battery charging schedule. The batteries have unique battery charging methods. For instance, one technique is optimized for charging speed. Another might be optimized for energy efficiency.
The relationship between the battery charging schedule and the onboard battery charger
The battery on a fork truck can be recharged a limited number of times. After reaching its limit, it does not charge as it used to be. Its ability to deliver amperes gets low. The performance of trucks suffers.
So the onboard battery charger should follow recommended maintenance schedule. A well-managed strategy may significantly increase the life of a truck's battery. A standard fork hoist battery has 1500 charging cycles. That means that if it is charged once daily, it will last for the whole of its five-year useful life. However, if it is charged twice a day, the battery will last two and a half years rather than the standard five years . Takeaways
The battery charger you choose for your forklift truck should be a well-thought-out decision since it directly impacts the performance of your forklift truck.
If you're looking for battery chargers for a forklift manufactured by a different OEM, please visit our website for a complete listing of onboard battery chargers.
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