What are the operational implications of charging at a higher rate?

Initial Cost: Initial charger investments may cost up to 5 times more than a conventional charger operation, especially if the charging system utilizes a dedicated charger for every battery.

Infrastructure Change: Once committed to the Fast or Opportunity charge process, it can be very difficult to transition back to Conventional charging or terminate the program. Additional investments and infrastructure changes can be costly including supplying adequate AC power, a water source for an eye wash station(s), and ventilation equipment to meet OSHA and safety requirements in the park and charge location(s). The elimination of a room or area dedicated for battery charging to save space may seem beneficial. However, once that space is occupied it can be very difficult to revert back to a designated battery area.

Battery Life: Battery life in a Fast or Opportunity charge operation will be shorter than in a Conventional charging operation. In a Fast or Opportunity charge operation, the life of the battery is measured by Ampere-Hour throughput, not length of time or traditional cycle life. Conventional charge battery life is measured in cycles, typically one cycle per day, 300 cycles per year, 1,500 cycles over 5 years.

A way to measure a lead-acid battery’s service life is ampere-hour (AH) throughput. Charging methods, material handling applications, number of cycles per 24 hour period, electrolyte temperature, and battery and charger maintenance practices will affect the speed of AH throughput. This directly dictates the length of the battery’s life. For example, use of Opportunity or Fast Charge methods accelerates AH usage more than if charging at a Conventional rate. This is a direct result of the increased material handling application demands on the battery, including higher charge rates, elevated electrolyte temperature, and operating the battery in a partial state of charge. In addition, if recommended discipline and guidelines are not for any type of charging, battery life will be adversely affected

Operational Alterations: An additional consideration is a possible alteration to employee breaks, lunch periods, and staggered shifts. These downtimes are needed for recharging and have to be at the right time to maximize battery productivity and operational needs.

Another alteration is a change in lift truck usage. In Conventional charging, a spare battery allows the truck to remain in use while the battery is charging. In a Fast or Opportunity charging, the battery is being charged while remaining in the truck and it cannot be used while charging. In some instances, this could have a significant impact on the allocation efficiency of material handling equipment resources.

What are some key practices for a Fast or Opportunity charge operation?

Key 1: The EverExceed agent salesperson, customer, and Fast/Opportunity charge supplier have worked together to measure the battery power requirements for each forklift type, time to recharge the battery, and allocate sufficient time for a weekly equalize charge.

Key 2: Battery average daily electrolyte temperature range between 50°F (10°C) to 120°F (49°C) during daily operation.

Key 3: Daily battery AH throughput is 1.25 to 1.6 times the 80% rated capacity of the battery being used.

Key 4: Batteries should receive a full recharge on a daily basis and an equalized charge every week. If the battery can only be recharged to a minimum 80 percent state of charge on a daily basis, than weekly full charge along with an equalize charge will provide acceptable service life.

Key 5: Charger start rates should be 21-60 amps per 100 AH. Higher start rates will significantly shorten battery life. The maximum start rate recommended by EverExceed is 40 amps per 100 AH.

Key 6: Batteries designed for Fast or Opportunity charging include modifications to improve conductivity such as copper inserted posts, dual cables, double stacked intercell connectors for best performance and longer life.

Key 7: A standard gravity battery design (1.290 specific gravity) should be used in a Fast or Opportunity charging operation to optimize battery life. We do not recommend using batteries with full charge specific gravity in excess of 1.290 and/or product designed for reduced watering or maintenance applications.

Key 8: Battery trays should have air gaps where possible to dissipate additional heat from higher charging rates.

Key 9: User discipline and willingness to connect to the charger as prescribed.

Key 10: Continuous measurement of AH throughput.

Key 11: Proper battery maintenance in accordance with the EverExceed Battery Service Manual.

If you have any requirements or any kind of query regarding the battery charger solutions, feel free to communicate with our dedicated team at any time at marketing@everexceed.com.