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 Points	Risk 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 lighting (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 Step	Inspection Item	Inspection Tool	Qualification Standard	Handling 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.
3	Site Safety	Visual Inspection	No debris, no flammable materials, and fire extinguishers in place.	Clean up debris and replenish fire extinguishers.
4	Power Supply 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.

News

Environmental Requirements for Equalizing Charging of Electric Forklift Batteries