Environmental Requirements for Equalizing Charging of Electric Forklift Batteries

2025-11-28 Visits:

Environmental Requirements for Equalizing Charging of Electric Forklift Batteries (Structured Practical Standards)

The environment for equalizing charging of electric forklift batteries directly affects the equalization effect, battery lifespan, and safety. Based on the characteristics of lithium - ion batteries / lead - acid batteries, it is necessary to define quantitative standards for the five core dimensions of "temperature, ventilation, humidity, site safety, and power supply conditions". The following are actionable environmental specifications:

1. Core Environmental Requirements (Dimension - based Quantification)

Environmental

 Dimension

Requirements

 for 

Lithium 

- ion Batteries

Requirements for

 Lead - acid 

Batteries

Practical Key PointsRisk Tips

Temperature 

Control

Charging 

environment 

temperature:

 5℃ - 40℃ 

(optimal 15℃ - 30℃)

Charging 

environment

 temperature:

 0℃ - 40℃ 

(optimal 10℃ - 30℃)

1.Install a thermometer for real - time monitoring

and pause charging immediately

if the temperature exceeds the threshold.


2. Use exhaust fans 

to cool down in high temperatures 

and pre - heating devices in low temperatures 

(avoid charging 

when the temperature is < 5℃).

3. Keep the distance between the battery 

and heat sources 

(such as radiators, 

engines) ≥ 1m


Temperature > 45℃: 

Triggers BMS over - temperature protection (BMS002) and accelerates cell aging.

Temperature < 0℃:

 Lithium - ion batteries cannot be equalized, 

and lead - acid batteries are prone to crystallization and sulfation.

Ventilation 

Conditions

Natural 

ventilation:

 Air change rate 

≥ 3 times / hour.

Forced ventilation:

 Air speed ≥ 0.3m/s

Natural 

ventilation:

 Air change rate 

≥ 5 times / hour.

Forced ventilation: 

Air speed ≥ 0.5m/s

1.Open doors and windows to ensure air circulation.

2. Install exhaust fans / ventilation ducts 

in enclosed spaces 

(such as basements, 

cold storage).

3. The charging area for lead - acid batteries should 

be far away from densely populated areas.


Poor ventilation: 

Heat dissipation 

of lithium - ion batteries is blocked,

 and hydrogen gas accumulates in lead - acid batteries 

(there is an explosion risk 

when the concentration > 4%).

Humidity 

Control

Relative

 humidity:

 40% - 80% 

(no condensation)

Relative humidity:

 30% - 85%

 (no condensation)

1.Use a hygrometer for monitoring

and close the doors

and windows on the humid side

on rainy days.

2. Lay anti - slip mats on the ground 

to avoid water accumulation.

3. Apply anti - rust agent 

to battery terminals

 (in humid environments).


Humidity > 85%: 

Causes short circuits, 

terminal oxidation,

 and triggers communication faults (BMS004).

Condensed water: 

Damages the battery BMS module.

Site 

Safety

1.The ground should be

level

(slope ≤ 3°)

with no sharp debris.

2. Keep a distance of 

≥ 1m from

 flammable materials

 (such as gasoline, 

cartons).

3. Do not place metal tools 

on top of 

the battery.

4. Equip with dry 

powder fire extinguishers 

(Class ABC) 

with a distance ≤ 5m.


1.The ground should be level

(slope ≤ 3°)

and corrosion - resistant 

(to prevent 

electrolyte leakage).

2. Keep a distance 

of ≥ 5m from fire 

sources and sparks 

(such as welding machines, 

smoking areas).

3. Set up an 

electrolyte leakage tray 

(volume ≥ 1.2 times 

the battery capacity).

4. Equip with dry powder 

fire extinguishers 

(Class ABC)

 with a distance ≤ 3m.


1.Clean up debris

in the charging area,

define an exclusive charging area 

(and paste warning signs).

2. Treat the ground 

in the lead - acid battery 

area with anti - corrosion measures 

(such as laying acid - resistant floor tiles).

3. Prohibit welding, 

grinding, 

and other operations that generate sparks 

in the charging area.


Substandard site conditions:

 Easily lead to battery 

tipping, 

short circuits,

 and fires.

No protection: 

Electrolyte leakage from 

lead - acid batteries 

corrodes equipment, 

and hydrogen gas explodes 

when exposed to sparks.

Power Supply 

Conditions

1.Input voltage

fluctuation ≤ ± 5%

(e.g.the fluctuation range

of 220V power supply is 

209V - 231V).

2. Grounding

 resistance ≤ 4Ω.

3. Independent circuit 

(do not share sockets

 with high - power 

equipment).


1.Input voltage

fluctuation ≤ ± 10%

(e.g., the 

fluctuation range 

of 220V 

power supply is 

198V - 242V).

2. Grounding 

resistance ≤ 4Ω.

3. Conductor cross - sectional

 area ≥ 2.5mm²

(to avoid overloading 

and heating).


1.Use a multimeter to detect the power supply voltage

and install a voltage stabilizer 

if the fluctuation

exceeds the standard.

2. Regularly check that plugs 

and sockets are free 

from looseness and oxidation.

3. Protect the charging circuit 

with pipes to avoid crushing.


Large voltage fluctuations:

 Equalizing charging fails 

(the voltage difference between

 individual cells cannot be eliminated).

Poor grounding: 

Risk of electric shock 

and damage 

to the charger and battery.

Lighting 

Conditions

Natural light 

or soft artificial lightin

(brightness ≥ 200lux)

Natural light 

or soft artificial lighting 

(brightness ≥ 200lux)

1.Avoid direct sunlight

on the battery

(use a sunshade to block it).

2. Turn on explosion - proof lighting lamps 

in the lead - acid battery

 area during night charging.


Direct sunlight: 

Causes the battery temperature

 to rise sharply 

and accelerates aging.

Insufficient lighting:

 Operational errors 

(such as wrong wiring).

2. Environmental Adaptation Schemes for Different Scenarios

2.1 Indoor Warehouses (Conventional Scenarios)

  • Temperature: Turn on industrial fans / air conditioners in summer (control the temperature ≤ 35℃) and close doors and windows to keep warm in winter (maintain the temperature ≥ 5℃).
  • Ventilation: Install exhaust fans (1 fan per 10㎡, power ≥ 30W) and turn them on regularly (ventilate for 15 minutes every 2 hours).
  • Safety: Define warning lines for the "battery charging area", post "No Smoking, No Open Flames" signs, and equip with fire extinguishers.

2.2 Low - Temperature Environments (Outdoors in Winter / Cold Storage, Temperature < 0℃)

  • Lithium - ion batteries: First move them to room temperature (≥ 5℃) for pre - heating for 2 hours, then perform equalizing charging.
  • Lead - acid batteries: Build temporary insulation sheds (using insulation cotton + heating lamps to control the temperature ≥ 5℃), and prohibit direct equalizing charging in environments where the temperature is < 0℃.
  • Note: The insulation shed must have ventilation openings (to avoid hydrogen accumulation), and the distance between the heating lamp and the battery should be ≥ 1m (to prevent overheating).

2.3 High - Temperature Environments (Outdoors in Summer / Workshops, Temperature > 40℃)

  • Ventilation: Turn on forced exhaust fans + spray cooling (avoid spraying directly on the battery) to control the environmental temperature ≤ 38℃.
  • Charging Time: Avoid the high - temperature period at noon and choose to charge in the early morning or at night.
  • Battery Protection: Cover the battery case with heat - insulating cloth (do not block the heat dissipation ports) to avoid direct sunlight.

2.4 Humid Environments (Rainy Days / Cold Storage, Humidity > 80%)

  • Dehumidification: Turn on the dehumidifier (control the humidity ≤ 75%) and lay water - absorbing mats on the ground.
  • Battery Protection: Cover the top of the battery with a waterproof cover (expose the heat dissipation ports), wipe the terminals clean with a dry cloth, and then apply conductive paste.
  • Charging Equipment: Choose chargers with a waterproof rating of IP54 or above, and use waterproof boxes to protect plugs and sockets.

3. Environmental Inspection Process (Must be Done Before Charging, Completed in 5 Minutes)


Inspection 

Item

Inspection 

Tool

Qualification StandardHandling Method for Disqualification
1

Temperature

 / Humidity

Thermohygrometer

Lithium - ion batteries:

 5℃ - 40℃, 

40% - 80%.

Lead - acid batteries: 

0℃ - 40℃,

 30% - 85%.

If the temperature exceeds the standard:

 Cool down / pre - heat.

If the humidity exceeds the standard: 

Dehumidify / ventilate.

2

Ventilation

 Condition

Anemometer

 (optional)

Natural ventilation:

 No peculiar smell, 

good air circulation.

Forced ventilation:

 Air speed ≥ 0.3m/s 

(for lithium - ion batteries) 

/ 0.5m/s 

(for lead - acid batteries).

Poor ventilation:

 Turn on exhaust fans 

and extend the ventilation time.

3Site Safety

Visua

Inspection

No debris, 

no flammable materials,

 and fire extinguishers in place.

Clean up debris 

and replenish fire extinguishers.

4

Power Suppl

y Voltage

Multimeter

Fluctuation ≤ ± 5%

 (for lithium - ion batteries) 

/ ± 10% 

(for lead - acid batteries).

Install a voltage stabilizer 

or replace the 

power circuit.

5

Grounding

 Condition

Grounding

 Resistance Tester

≤ 4Ω

Re - ground and replace

 the grounding electrode.

4. Prohibited Requirements (Red - line Provisions)

  • It is prohibited to perform equalizing charging in enclosed spaces (such as elevators, containers).
  • It is prohibited to charge in outdoor rainy conditions or on water - logged ground (unless equipped with professional waterproof facilities).
  • It is prohibited to force equalizing charging in environments where the temperature is > 45℃ or < - 10℃.
  • It is prohibited to charge lead - acid batteries and lithium - ion batteries in the same area (the risks of hydrogen gas and heat dissipation of lithium - ion batteries overlap).
  • It is prohibited to stack flammable, explosive, and corrosive materials in the charging area.
  • It is prohibited for non - professional personnel to modify the charging environment (such as removing ventilation equipment, blocking heat dissipation ports).

5. Summary

The core of the environment for equalizing charging is "stability, safety, and adaptation to battery characteristics". Lithium - ion batteries focus on temperature and power supply stability (to avoid triggering BMS protection), while lead - acid batteries focus on ventilation and leakage prevention (to avoid hydrogen explosion and electrolyte corrosion). Through quantitative standards + scenario - based adaptation + pre - charging inspection, the safe and effective operation of equalizing charging can be ensured, and at the same time, fault codes (such as BMS002 over - temperature, BMS004 communication fault) and battery damage caused by improper environment can be reduced.


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