The State of Charge Gauge is a string of LEDs which display the following:
Total cost of ownership, or TCO, represents the complete cost of purchasing, operating, maintaining, charging, and replacing a battery over its service life. For an industrial equipment fleet, TCO can include the battery purchase price, maintenance labor, energy consumption, battery changeouts, downtime, charging infrastructure, replacement batteries, and battery room space.
Lithium-ion batteries can reduce total cost of ownership by eliminating watering and many routine maintenance tasks, improving charging efficiency, supporting opportunity charging, reducing battery changeouts, and providing a longer service life. The actual savings depend on fleet size, operating hours, labor rates, energy costs, charging practices, and the number of shifts.
A forklift battery total cost of ownership analysis should consider:
Flux Power offers a forklift battery ROI calculator that compares lithium-ion and lead-acid battery costs over a five-year period. The calculation can include battery purchases, maintenance, labor, energy use, changeouts, facility space, and other operational expenses. Because every fleet operates differently, a customized assessment provides the most useful estimate.
Flux Power’s patented Battery Management System (BMS) monitors charging so that the pack cannot be over charged or over discharged. The only risk is if someone fully discharges the battery pack and then does not plug it in. In this case, because of the small parasitic draw from the electronics, it is possible to completely kill the pack. Therefore, we recommend the packs remain plugged in whenever not in use for more than a few days. There is no harm in leaving the packs plugged in, but great harm if they are left discharged for extended periods of time.
Note: Allowing the battery to over discharge due to extended use or storage after the low SOC alarm goes off will results in an “over discharge” condition and the battery will no longer charge. Failure to properly maintain the batter will void the batteries warranty
There is no point at which a discharge counts as 1 cycle. Each cycle puts wear on the battery proportional to its depth of discharge. If the battery is discharged to 80% every cycle, it will last ~ 2000 cycles. If the battery is cycled at 70% DOD, the battery will last ~3,000 cycles.
This has a nonlinear effect on the total amp-hour throughput of the battery over its lifetime. The smaller the DOD is, the larger the total Ah output of the battery is. Comparing the lifetime output of two 100 Ah batteries at 80% and 70% DOD, the total Ah output can be idealized by the following:
100Ah*0.8DOD*2000=160,000Ah total output.
100Ah*0.7DOD*3000=210,000Ah total output.
In reality, the total lifetime output numbers will be closer together, as factors such as battery aging are not being considered, however the 70% DOD battery will still output more Ah over its lifetime. This is the main reason why opportunity charging is a perfect fit for LiFT Packs.
There are several different chemistries available. Flux Power uses LiFePO4 due to its long cycle life, low cost of ownership, thermal stability, and high-power output. Below is a chart which provides some information on alternative lithium-ion chemistries.
| Specifications | Li-cobalt LiCoO2 (LCO) | Li-manganese LiMn2O4 (LMO) | Li-phosphate LiFePO4 (LFP) | NMC1 LiNiMnCoO2 |
| Voltage | 3.60V | 3.80V | 3.30V | 3.60/3.70V |
| Charge Limit | 4.20V | 4.20V | 3.60V | 4.20V |
| Cycle Life | 500 | 500 | 2,000 | 2,000 |
|
Operating Temperature |
Average | Average | Good | Good |
| Specific Energy | 150–190Wh/kg | 100–135Wh/kg | 90–120Wh/kg | 140-180Wh/kg |
| Loading | 1C | 10C, 40C pulse | 35C continuous | 10C |
| Safety | Average | Average | Very Safe | Safer than Li- Cobalt |
| Thermal Runway | 150°C (302°F) | 250°C (482°F) | 270°C (518°F) | 210°C (410°F) |
As lithium iron phosphate cells cycle, the charge is carried between the anode and cathode using lithium-ions. As the pack cycles a very small percentage of the mobile lithium-ions are caught in irreversible side reactions. This reduces the amount of charge transfer possible between the electrodes.
In lead acid this is somewhat analogous to sulfation, where the sulfur becomes locked in stable lead sulfite crystals and can no longer intercalate into the lead plates. Sulfation is worse however as it occurs during use and during storage, the crystals can grow and crack the plates, and block electrolyte access to the plates.
When the battery charges, the lithium ions are in the carbon/graphite anode, and when discharging the lithium ions move to the cathode. The chemical reactions are as follows:
• Charge : LixC6 = 6C + xLi + xe
• Discharge : Li(1-x)FePO4 + xLi+ xe = LiFePO4
It is difficult to compare a lithium-ion and lead acid battery when only looking at amp hours. Flux Power uses amp hour equivalent to give a better estimate of the run-times you should expect. The voltage is higher and stays higher, meaning there's more energy (kWh) in the battery pack, for a given amp hour rating.
In addition the pack is lighter, and the chemistry is more efficient, so you save energy charging and discharging, and use less while running the equipment. You can also drain more of the energy from the battery without serious effects, meaning for identical amp-hour ratings, lithium-ion will run longer. This is why we call our 100Ah lithium-ion pack a 135. It will run as long (or longer) than a 135Ah lead acid.
At the end of its useful service life, a Flux Power lithium-ion battery can be returned for responsible recycling. Flux Power provides customers with an end-of-life program designed to support the compliant handling, transportation, processing, and material recovery of industrial lithium-ion batteries.
Flux Power commits to accepting Flux Power lithium-ion batteries that customers return for recycling at the end of their useful life. Customers may also work with an approved local recycling provider. Return transportation and other requirements may vary, so customers should contact Flux Power Support before shipping a battery.
Specialized lithium-ion battery recycling processes can recover valuable materials from used cells and modules. These materials can then reenter the battery supply chain or be used in other applications, supporting a more circular approach to battery lifecycle management.
Industrial lithium-ion batteries must be packaged, handled, and transported in accordance with applicable hazardous materials and transportation regulations.
Customers should not ship or dispose of a battery without first receiving proper instructions. Flux Power can provide guidance on the appropriate next steps.
There are several factors responsible for the remarkable safety of Flux Power lithium-ion batteries.
The lithium-ion cells are first encased in hard plastic, and then an industrial 10-gauge powder coated steel case. If a user punctures through all these materials and exposes the lithium-ion cell electrodes and electrolyte, be cautious when handling. The electrolyte consists of organic solvents (EC, PC, DEC) and a dissolved electrolytic salt (LiPF6). They are skin and eye irritants, and fumes can cause mucus membrane irritation.
The solvents are flammable so do not expose to an open flame. Use rubber gloves, eye protection, ventilation and positive pressure breathing protection when removing the damaged battery and electrolyte. In addition, LiPF6 is hydrophilic and reacts with water releasing hydrogen fluoride, a corrosive flammable gas. If a fire does occur, use a CO2 or chemical fire extinguisher.
Flux Power uses lithium iron phosphate (LFP) in its products as it is a very stable chemistry. The burn temperature is over 500F, much higher than other chemistries such as lithium cobalt at 149C (300F). The chemical stability also provides long cycle lifetimes (2000 at 80% DOD). In addition, there are safety measures built into the pack which prevent overcharging and rapid discharging. Finally, the battery case is made of high-grade steel, protecting the cells from damage, and containing them should a cell breach occur.
All these protections mean that under normal usage there is no danger of a fire. The dangers of spills and explosive gas buildup from lead acid batteries are much more common than a LiFT Pack catching fire.
Flux Power offers lithium-ion battery models that have been evaluated by UL Solutions and carry applicable UL Listings or Recognitions in the U.S. Certifications vary by product family, model, voltage, and application, so customers should review the documentation for the specific battery being considered.
A UL Listing indicates that a product has been independently evaluated by UL Solutions against applicable safety requirements for its intended use. UL testing may evaluate areas such as electrical safety, mechanical integrity, environmental conditions, and protection against abnormal operating conditions.
Flux Power has received UL EE Listing in the U.S. across its material-handling lithium-ion battery portfolio, including applicable S-Series, M-Series, L-Series, and X-Series energy solutions. UL EE designation is particularly important for equipment operating in environments where combustible dust or other hazardous materials may be present. Customers should confirm that the specific battery and lift-truck combination meets the requirements of their application.
The applicable standard depends on the product and intended application. Certain Flux Power energy solutions have been evaluated under standards such as UL 2271, UL 2580, and UL 1973. Flux Power’s G80-G2 ground support equipment energy solution, for example, has achieved UL 1973 Listing.
Customers should consult the product documentation or Flux Power team to verify the listing associated with a specific model.
Lead acid:
When a single cell fails, there is no BMS to manage the charging. Therefore the failing cell will heat up, but not fully charge. The failing cell will accelerate its decline as it is used improperly and cause the entire pack to drain rapidly when in use. As an example, if a failing lead acid cell is at 50% capacity, the charger will not attempt to charge it to its full (diminished) capacity, this means that once the pack is used, the voltage drop will be significant in this cell, and the entire pack will see a drastic drop in run-time due to the low voltage in this cell.
Flux Power lithium-ion battery:
When a single cell begins to fail, the entire pack will experience a reduction of run-time proportional to the single failing cell’s reduction in run time. The BMS will still charge and balance the cells, but the pack will cut off when the failing cell voltage drops to 2.8 Volts. As an example, if the failing cell is at 50% capacity, the charger will still charge the cell to full (diminished) capacity and the cell will produce the expected voltage, just for 50% shorter run-time. The pack will then run as if it has 50% capacity. The BMS will protect the other cells from harm due to a low cell. The BMS avoids the low voltage scenario which is problematic in lead acid.
Lithium-ion cells have a higher nominal voltage than lead acid. The Flux Power LiFT pack is comprised of an array of 8 lithium-ion cells connected in series or parallel, each with a nominal voltage of 3.2V. The pack nominal voltage is therefore the summation of the number of cells in the battery. There is minimal voltage drop as the pack discharges under normal use. The pack will indicate it needs to be charged when it drops to 3.0 volts per cell. See the table below for a summary of the different lithium-ion nominal voltage compared to lead acid nominal voltage.
|
Lead Acid (nominal) |
24V |
36V |
48V |
80V |
|
Flux Power Lithium-ion (nominal) |
25.6V |
38.4V |
51.2V |
76.8V |
Yes. Flux Power lithium-ion batteries are supported by a limited warranty covering eligible defects in materials or workmanship. Warranty length, operating-hour limits, coverage, and conditions may vary by product model and application. Customers should review the limited warranty provided with their specific battery for complete terms and exclusions.
Warranty coverage varies by product family, model, and application. Some Flux Power products have historically included five-year or application-specific limited warranties, while certain ground support equipment products may have different coverage terms. To avoid presenting outdated or incorrect coverage, customers should refer to the warranty document associated with their battery’s exact model and serial number.
Subject to the applicable limited warranty, coverage may include qualifying defects in materials or workmanship. The available remedy, such as repair or replacement, is determined according to the warranty terms. Normal wear, misuse, improper charging, unauthorized modifications, incorrect installation, or operation outside specified limits may not be covered.
Contact Flux Power Support with the battery model, serial number, operating hours, equipment information, purchase details, and a description of the issue. Photographs, diagnostic information, service records, or returned components may also be requested. Do not return a battery or component unless Flux Power has provided instructions and, when required, a return material authorization.
Register a Flux Power Warranty and Flux Power Product Support
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