SUA2200xli FLT charger with control Panel

We had a problem with the charger that came with our Fork lift truck. It would never turn off at the right voltage - it would initially charge too fast and gas the cells a lot, and then if you left it on for over a weekend it would discharge the cells again, leaving the truck showing 10% charge on Monday morning. It would also draw a lot of power during this whole process. The charger MFR manual shows changing the transformer taps, which we did, but that didnt help.

We came up with a better solution in using one of our UPS (an SUA2200xli) as a charger. This is a low power charger - using only around 400 watts peak charging power - BUT it is intelligent. We can plug this in and it will slowly charge the fork truck up and then trickle charge to maintain it.

We have been using this method for years.
I include several photos showing our setup.

If you have a fork lift truck that has light use that does not need rapid charging this is perfect. We also have days where we unload containers, on those the fork truck has been fine and we leave on charge over night and the next day its back to full again.

We have always had this problem of FLT chargers being designed for high power charging, but leave a lot to be desired in intelligent charging. Since starting to use the UPS we've noticed not having to fill as much water, and the cells dont gas / get hot under charging.

Battery system 48VDC nominal
Charging power 271W

The power draw reduces when the fork truck battery cells are increasing in charge, until the UPS is not drawing much, just maintaining the battery state.

Input voltage 210-250VAC
Single phase
Standard UK wall plug - we include the lead

Dimensions
Maximum Height 444.0 mm
Maximum Width 221.0 mm
Maximum Depth 495.0 mm + a little room for the cable to go in

40KG

We've attached some photos from one of our customer's installations. He uses the UPS to charge the large cell bank overnight. When there has not been much solar generation during the day, he plugs his car (which has a vehicle to load capability) into the UPS, which then slowly lifts the voltage of the cells overnight.