The battery marked 48V 24-100-21 (38.65″x32.88″x25.5″) is a 48-volt industrial lithium-ion battery, likely designed for material handling equipment like forklifts or automated guided vehicles (AGVs). The 24-100-21 code typically denotes capacity (≈100Ah), cell arrangement (24S for lithium), and design revision, while the dimensions align with Class I/II forklift battery compartments. Its LiFePO4 chemistry ensures 2,000–4,000 cycles at 80% DoD, outperforming lead-acid counterparts. How Much Does a Forklift Battery Weigh?
How is 48V 24-100-21 structured?
This lithium battery employs a 24-series (24S) LiFePO4 cell configuration to achieve 48V nominal (51.2V working). Each 3.2V cell contributes to a total 153.6V max charge, managed by a 200A-rated BMS. Pro Tip: Check terminal polarity—some models use reverse L-terminals to prevent accidental mismating.
Deep Dive: The 38.65″x32.88″x25.5″ size matches standard 48V lead-acid replacements, enabling drop-in upgrades. Internally, 24 prismatic LiFePO4 cells (100Ah each) are arranged in 4×6 blocks. Practical Example: A Raymond reach truck retrofitted with this pack gains 30% runtime but weighs 450 lbs less than lead-acid. Transitioning, BMS safety features include temperature cutoff at 140°F and cell-level fuses.
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What applications suit this battery?
Optimized for high-cycle forklifts and multi-shift warehouse robots, its IP54-rated casing handles dust/debris. Voltage stays above 46V even at 20% SoC, crucial for hydraulic pumps. Pro Tip: Use CAN-enabled chargers to log cycle data and predict cell aging.
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Deep Dive: In Class II electric forklifts, this pack delivers 7–10 hours runtime under 50% load. Comparatively, lead-acid versions provide 5–7 hours but require 8-hour cooldowns. What makes lithium superior? No memory effect allows opportunity charging—5-minute top-ups during breaks add 15–20 minutes runtime. Table below contrasts performance metrics:
| Parameter | 48V LiFePO4 | 48V Lead-Acid |
|---|---|---|
| Cycle Life | 3,000 | 1,200 |
| Charge Time | 2 hrs | 8–10 hrs |
How does weight compare to lead-acid?
At ~1,100 lbs, it’s 40–50% lighter than similar-capacity lead-acid batteries (2,000–2,500 lbs). Reduced mass improves forklift acceleration and brake longevity. Pro Tip: Always recalculate load margins—lighter batteries alter vehicle center of gravity.
Deep Dive: The weight difference stems from lithium’s 150–200 Wh/kg density versus lead-acid’s 30–50 Wh/kg. For perspective, swapping a 2,300-lb lead-acid unit with this 1,100-lb lithium pack is like replacing a grand piano with a pool table—same energy, less strain. Transitionally, warehouses report 12–18% energy savings from reduced motor effort.
What charging systems are compatible?
Requires 54.6V CC-CV lithium chargers with CAN or RS485 communication. Bulk charging at 100A fills 100Ah in 1 hour, but 50A is safer for cycle longevity. Pro Tip: Avoid three-phase chargers unless BMS supports active balancing during fast charges.
Deep Dive: Charging profiles vary by temperature—below 32°F, the BMS limits current to 20A to prevent plating. A real-world example: Jungheinrich ETR 106 forklifts using Delta Q IC650 chargers achieve 95% efficiency. Table compares charger types:
| Charger | Voltage | Current |
|---|---|---|
| Standard | 54.6V | 50A |
| Fast | 54.6V | 100A |
How to maintain this battery?
Lithium requires minimal maintenance—no watering, equalizing, or acid spills. However, monthly SOC calibration via full discharge/charge cycles prevents BMS drift. Pro Tip: Store at 50–60% SOC if idle for >3 months to minimize degradation.
Deep Dive: Unlike lead-acid, sulfation isn’t a concern, but cell imbalance can occur after 800+ cycles. Imagine the battery as a choir—if one singer (cell) goes off-key, the BMS (conductor) readjusts harmony via balancing resistors. Transitionally, cloud-connected BMS platforms like Redway’s Telematics Pro send alerts when cell delta exceeds 50mV.
Redway Battery Expert Insight
FAQs
Yes, if compartment dimensions and terminals match. However, update charger protocols—lead-acid settings overcharge lithium.
Does cold storage damage lithium batteries?
No, but charging below 32°F requires BMS preheating. Discharge is safe down to -4°F at reduced capacity.
