Material Handling Battery Charging
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APP Anderson Power Products® An Ideal Company Choosing the Correct APP® Connectors Based on Battery Charging Technologies Material Handling Battery Charging Material Handling Equipment charging trends are changing. This application document offers a brief explanation of the charging technologies, the pros and cons of each, and then will describe the appropriate APP® products to recommend and the attributes to discuss that make APP® the correct partner for their needs. Traditional Conventional Charging - Charging requires 8-10 hours to fully recharge the battery allowing one shift per battery and requires multiple batteries, as well as changing equipment, to run multiple shifts. New Trends Opportunity Charging - Charging at every possible opportunity (lunch and breaks, between shifts, etc.) to extend battery shift life and minimize changeover/downtime. Fast Charging - Charging at every possible opportunity and at 3-4 times the rate of conventional systems with power requirements often exceeding 600 amps.

Conventional Charging Conventional Charging - Best Suited for Single Shift Warehouses Batteries are charged at rates of 16-18 amp/100 amp hours and takes about 8-10 hours to fully recharge the battery. A battery is charged using the 8-8-8 rule: the battery charges over an 8-10 hour period, rests and cools down for another 8 hours and is used (discharged) over an 8 hour shift. Positives 1. Uses existing or standard chargers that are less expensive. 2. No need to move from lead acid batteries (purchased cost is least expensive on the market). 3. Uses existing warehouse infrastructure for...

Opportunity Charging Opportunity Charging – Best Suited for Multi-shift Operation Batteries are charged at rates of 25 amp/100 amp hours at every possible opportunity (i.e. lunch breaks, between shifts) for anywhere from 10 -30 minutes and charges battery to 80 -85% state of charge (SOC) and 100% charge overnight. Once a week the battery must be fully charged to 100% typically on weekends. Positives 1. Excellent choice for extended shift operations or 2 shift operations where battery changing can be eliminated. 2. Opportunity charging extends the run time of aging batteries and recoups the...

Negatives 1. Initial costs are higher as fast charging batteries are approximentally 25% more expensive (batteries require alternate internal design and a thermistor for temperature communication) and chargers are approximentally 400% more expensive (includes battery management system (BMS) for temperature/ charge control). 2. Battery life is shorter (approximentally 3 years versus 5 years in conventional charging). 3. Higher charging rates (up to 640 amps) require connectors between charger and battery using larger stiffer, cables (350MCM or larger). Alternately dual runs of stacked...

Charging Connectors SB® Product Family – SB®50, SB®175, SB®350 Conventional Charging and Opportunity Charging 1. Provides a wide range of cable sizes and up to 550 amps maximum. 2. Signal contacts are not required in conventional charging. 3. Color and mechanically keyed for voltage. 4. Low cost, robust, and easy to assemble. 5. 10,000 mating cycles ideal for multiple daily charge cycles. Fast Charging *Not recommended for fast charging due to lack of auxiliary contacts for communication between BMS and battery. APP® Competitive Edge 1. 2. 3. 4. 5. APP® original designer of SB®/SBX®series...

Charging Connectors SBE® Product Family (80, 160, 320) , SBX® Family (175, 350) Conventional, Opportunity, and Fast Charging 1. Provides a wide range of cable usage and up to 550 amps UL maximum (SBE® and SBX®). 2. Color and mechanically keyed for voltage. 3. SBE® meets EN1175-1 requirements. 4. Especially useful for Fast Charging – up to 8 auxiliary contacts available for charger/battery communication and auxiliary contacts can be used in conventional/opportunity charging for power on/off, digital signage, or vehicle lockout. 5. 10,000 mating cycles. APP® original designer of SBE®/SBX®...

Charging Connectors Continued A and E Series DIN Product Family (80, 160, 320) Conventional, Opportunity, and Fast Charging 1. Provides a wide range of cable usage and UL rated up to 450 amps (A series only). 2. Universal housings with voltage keys that can be rotated based on voltage and color coded by battery type. 3. E series DIN meets 43589-1 standard and EN1175-1. 4. Especially useful for fast charging – up to 4 auxiliary contacts available for charger/battery communication and auxiliary contacts can be used in conventional/opportunity charging for power on/off, digital signage, or...

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