A Linde lithium-ion forklift battery can be fully charged in less than 90 minutes and topped up at any break without shortening its service life. It is designed to last at least 2,500 full charging cycles.
We get a lot of questions about how Li-ION batteries compare with lead-acid. This post answers the ones about charging, chargers, battery life and the power supply your site will need. Part Two covers safety, cold store use and compliance.
Can I treat lithium-ion batteries like lead-acid batteries?
No, lithium-ion technology differs significantly from traditional lead-acid technology. Lithium-ion batteries have a much longer service life, charge more efficiently and cost less to maintain. They also have special storage and transport requirements, covered in Part Two.
How many charging cycles is a lithium-ion battery designed to last?
Linde Li-ION batteries are guaranteed for at least 2,500 full charging cycles (a complete charge and discharge counts as one cycle). After 2,500 cycles the battery still holds at least 75% of its original capacity in warehouse trucks (24V) and at least 80% in electric forklifts, reach trucks and VNA trucks (48V and 90V products). Many lithium-ion batteries can even be used for a second truck life.
What effect do opportunity charges have?
Unlike lead-acid batteries, lithium-ion batteries can be opportunity charged with no noticeable effect on their overall service life. Lithium-ion batteries are also not subject to the "memory effect". The full energy capacity stays available no matter which range the battery is regularly charged and discharged within. These batteries perform best within a 20-90% State of Charge (SOC).
What are the key benefits of Li-ION technology?
Higher efficiency: Taking the battery and charger together, Li-ION batteries have up to 20% higher electrical efficiency than lead-acid batteries. Less energy is lost as heat and energy costs are lower.
Intermediate charging: Allows charging at any time (for example, during lunch breaks). Trucks stay available for longer and across multiple shifts.
Fast charging: Li-ION batteries charge faster than lead-acid batteries and can be charged during regular breaks. Faster charging also means one charger can serve several trucks. That reduces the cost and floor space needed for charging.
No battery change necessary: Most 2-shift applications do not require battery changes, saving costs and time.
Emission-free: Li-ION batteries do not emit hazardous gases or acids and do not contain toxic substances like cadmium, lead or mercury.
Maintenance-free: No daily maintenance like water refilling or battery cleaning is needed. There are no regular battery checks and no add-ons such as electrolyte circulation systems. 
What advantages do lithium-ion batteries bring to daily operations?
Lithium-ion batteries have a high energy density and a low self-discharge rate. They charge quickly, have a long service life and can be discharged down to approximately 5% SOC without affecting performance. A full charge takes less than 90 minutes depending on the battery and charger combination. Quick interim charges remove the need for battery changes. Maintenance costs are reduced and there is no need for a battery room. In daily operation that means:
No need for multiple batteries
No battery changes
No daily maintenance
High truck availability with less downtime
Efficient use of breaks for charging
Energy savings and a longer battery service life
Residual battery value after 2,500 cycles
Can I charge lithium-ion batteries with my normal battery charger?
No, only the corresponding Linde Li-ION charger is suitable, as it communicates with the battery via a CAN-Bus interface.
Can we have on-board chargers with Li-ION batteries?
Some 24V warehouse truck models have on-board charging available with Li-ION batteries.
How much mains current does each charger draw?
The battery and charger data sheets provide the 'Max AC current' figure and the primary peak power draw for each charger type. Data sheets are available for 24V, 48V and 90V batteries
What are the charging times?
A full charge takes less than 90 minutes, but the exact time depends on the battery and charger combination. Refer to the datasheets for 24V, 48V, and 90V batteries.
What are the minimum 20% to 100% charging times?
The 20% figure applies to lead-acid batteries, while a Li-ION battery can use 95% of its stored energy. For that reason the battery and charger data sheets show the charging times from 95% discharged to fully charged for each battery and charger combination. Li-ION chargers maintain a constant rate up to a certain SOC. The last 10-15% takes longer because the charger reduces its power to avoid overcharging the cells
How much current does the Li-ION charger draw compared to a HF charger?
Li-ION battery chargers generally have a higher output than high-frequency (HF) lead-acid chargers and require a higher input current as a result. Thanks to CAN-Bus communication, the most powerful charger in each voltage range can also charge the smallest battery in that range.
Can Li-ION batteries be charged via either 3-phase or single-phase supply chargers?
It depends on the battery voltage.
24V batteries (warehouse products) have one single-phase charger option. The other 24V chargers are 3-phase.
48V/90V batteries (counterbalance and reach) have only 3-phase chargers.
Do I need to make any changes to my electrical supply to accommodate the chargers?
We will work with you to check your current system's capacity. That means looking at your site's current energy consumption, its electrical infrastructure and the possible effects on peak power demand.
Are there any differences between a lithium-compliant charger and a standard charger?
The main differences are the higher current draw and the different circuit breaker and connector types that may be required.
How much energy will this technology need?
Because energy use depends on your fleet and how it is used, an energy survey is necessary to determine if your site can accommodate Li-ION batteries. Multi-shift sites running lead-acid often use more than one battery per truck and change them during the day. Li-ION batteries typically do not require changing. The survey checks that your trucks' working hours and the opportunity charging periods available will meet your application needs.
Safety, cold store use and compliance are covered in Part Two of our Li-ION FAQs. For a wider comparison with lead-acid, read Lithium-Ion Forklifts NZ: How Linde's Li-Ion Technology Outperforms Lead-Acid. Our post on the 10 common myths about lithium-ION batteries is also worth a look.
If your question isn't answered here, or you'd like to talk about moving your fleet to Li-ION, contact the LDX team. You can also browse our full range of electric forklifts.