Frequently Asked Questions by Wholesalers
Lithium Battery Product FAQ
Lithium Battery Advantages:
✅ High Energy Density: Smaller and lighter, ideal for space-constrained applications.
✅ Long Cycle Life: 2,000–4,000 charge cycles (compared to lead-acid’s 500–1,000 cycles).
✅ Maintenance-Free: No need for water refilling or equalizing charge; managed by BMS.
✅ Fast Charging: Fully charges in 1–3 hours (lead-acid requires 8–10 hours).
✅ Eco-Friendly: No lead or heavy metals, lower environmental impact.
Lithium Battery Disadvantages:
⚠️ Higher Initial Cost: 2–3 times the price of lead-acid.
⚠️ Limited Low-Temperature Performance: Requires heating system below -20°C.
Lead-Acid Battery Advantages:
✅ Lower Cost: More affordable upfront, suitable for budget-conscious buyers.
✅ Counterweight Benefit: Heavier design helps balance forklifts naturally.
Lead-Acid Battery Disadvantages:
⚠️ High Maintenance: Requires regular watering and terminal cleaning.
⚠️ Shorter Lifespan: Frequent replacements increase long-term costs.
📏 Standard Sizes: Common dimensions are length × width × height (e.g., 800×500×800mm), must fit forklift battery compartment.
🔧 Custom Sizes: Some lithium batteries can be custom-designed to fit tight spaces (e.g., AGV applications).
📋 Verification: Provide forklift model for manufacturer recommendations or installation drawings.
⚖️ Weight Considerations:
- Lead-acid batteries are heavier (e.g., 48V/600Ah ~1.2 tons) and help balance forklifts.
- Lithium batteries are lighter (~0.6 tons for the same capacity), requiring additional counterweight.
Solutions:
- Choose higher energy density lithium batteries to minimize weight differences.
- Add counterweight blocks at the rear of the forklift (consult manufacturer for safety).
⚡ Common Voltage Options:
- 24V: Small forklifts
- 48V: Standard forklifts
- 80V: Heavy-duty forklifts
📌 Voltage Matching:
- Always follow the forklift manufacturer’s voltage specifications.
- Higher voltage (e.g., 80V) is better for heavy loads and intensive operations.
🔌 Match the Battery Type:
- Lithium batteries require specialized chargers with BMS communication.
- Lead-acid batteries need constant voltage/constant current chargers.
📊 Power Calculation:
Charging current (A) = Battery capacity (Ah) ÷ Charging time (hours)
📍 Example: A 600Ah lithium battery requires a 300A charger for full charge in 2 hours.
🔍 Key Features:
- Lithium: Fast charging, temperature monitoring.
- Lead-acid: Trickle charging to prevent sulfation.
✅ Lithium Battery: Safe for long-term charging (BMS prevents overcharging), but unplugging when full saves energy.
⚠️ Lead-Acid Battery: Prolonged charging can lead to overcharging, water loss, and battery damage.
- Lead-acid: Charge when 20%-30% of battery capacity remains (avoid deep discharges).
- Lithium: Can be opportunity charged anytime without memory effect (shallow charges extend lifespan).
📌 Formula: Charging Current (A) = Battery Capacity (Ah) ÷ Desired Charging Time (hours)
📍 Example: A 600Ah battery needing 3-hour charge requires a 200A charger.
⚠️ Safety Limits:
- Lead-acid: Recommended charge rate ≤0.2C (e.g., 600Ah battery should not exceed 120A).
- Lithium: Can support up to 1C charging (e.g., 600A for 600Ah battery).
🔋 Cycle Life: 2,000–4,000 cycles (capacity retention ≥80%).
📆 Calendar Life: 8–10 years, even with low usage.
🛡️ Lifespan Extension Tips:
- Avoid high temperatures (>45°C).
- Store at 50% charge if not in use for long periods.
Lithium Battery:
- Charging: 0°C~45°C (requires heating below 0°C).
- Discharging: -20°C~60°C (cold temperatures reduce capacity).
Lead-Acid Battery:
- Optimal range: 25°C~30°C (high heat accelerates water loss, cold reduces performance).
❄️ Cold (-20°C):
- Lithium battery retains 70%-80% capacity (heated versions restore up to 90%).
- Lead-acid battery drops to 40%-50% capacity.
🔥 Hot (50°C):
- Lithium battery lifespan shortens without active cooling.
- Lead-acid battery suffers electrolyte evaporation & plate corrosion.
💰 Initial Cost: $0.20-$0.40 per Wh (48V/600Ah costs ~$5,000–$7,000).
| Cost Factor | Lead-Acid (5 years) | Lithium (5 years) |
|---|---|---|
| Purchase Cost | $10,000 | $25,000 |
| Energy Cost | $18,000 | $12,500 |
| Total Cost | $28,000 | $37,500 |
💡 Savings: Lower maintenance and downtime reduce long-term costs by ~30%.
- Lead-Acid: 2–3 years (single shift) or 1–1.5 years (three shifts).
- Lithium: 5–8 years (even in three-shift operations).
⚙️ Solutions:
- Add Counterweight Blocks to the forklift’s rear.
- Select higher-density lithium batteries that closely match lead-acid weight.
- Adjust forklift balance (e.g., reposition forks, install stabilizers).
- Lead-acid: If capacity drops below 60% or voltage drops quickly after charging.
- Lithium: BMS warnings or capacity falls below 80%.
- Lead-acid: Must be properly recycled to prevent lead pollution.
- Lithium: Requires certified recycling partners for safe disposal.
❌ No! Voltage and capacity mismatches can cause overload and uneven charging.
- Lead-acid: Disconnect immediately and clean with protective gear.
- Lithium: IP67-rated batteries resist short exposure but should be inspected.
- Lead-acid: Charge monthly to maintain 50% charge.
- Lithium: Charge every 3 months to 50-60%.
- Cell Defects: Up to 5 years.
- BMS Failure: 2 years.
- Physical Damage: Not covered.
