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When you go with the purchase, you like reassurance that everything works smoothly. However, when you sell something, you hope that you won’t receive a nasty comment soon. But many new systems and units exhibit minor issues when you run them the first time. Whether you are a seller or buyer, it is not a pleasing thing. That’s where a factory acceptance test comes into play. 

Now, don’t hesitate to start reading and learn everything about factory acceptance checks!

Factory Acceptance Test – An Overview

Caption: Manager and worker discussing the machine in a factory

Equipment suppliers do a factory acceptance test (FAT) before the buyer receives it. You test everything relevant to the equipment’s performance.  FAT usually consists of multiple tests and analyses. Generally speaking, we can divide the entire test into two categories:

• Static analysis. A static review covers a detailed check of safety, mechanics, electronics, and accompanying documents.
• Dynamic analysis. This part focuses on a performance test for the equipment. Most sellers perform a dry test, which doesn’t need using a product. Some brands test the operation with relevant materials used by the machine during actual production. That serves to ensure the equipment operates well and delivers the expected results.

Benefits of Testing 

Caption: A worker writing something on the clipboard

FAT is crucial for every side of the equipment transaction. 

The buyer wants to know the piece of equipment works, and FAT confirms that. These tests address safety concerns. A responsible owner knows the employee safety is a top priority. So, having a confirmation that the equipment is safe is essential.

For the seller, it’s much better to detect any issues while the product is in their facilities. So, if they uncover any problem, it’ll be easier to fix them on the premises. The problems detected could be the seller’s mistake, such as a non-working component. On the other hand, the buyer might ask for design reconfiguration, leading to various issues. Therefore, getting everything in perfect shape before sending the equipment to the buyer is imperative.

The Basic Factory Acceptance Test Checklist

Caption: Workers checking the machine

Generally speaking, the equipment type will affect the necessary tests. Also, the buyer might have specific requests for the gear.  It is hard to give a standard checklist, but the main categories are covered by formal testing.

A Detailed Inspection

The customer might require a specific verification. The seller usually starts by checking if the unit matches the drawings made in the production process. They also contain the nameplate data and any other details relevant to that equipment piece. Therefore, performing a practical test to confirm the relevant information might be necessary.

Water Test

This is a name for a test where the seller starts the equipment. The working process should prove functionality. The seller also checks the instructions, P&IDs, and other relevant documents. Therefore, these testing procedures confirm they are accurate.

Contract Audit

The seller should check the original contract. It’s the only way to confirm that the equipment meets all agreement points. Therefore, both sides are sure they follow the contractual specifications to the smallest detail.

The FAT Template for an Automated Reactor System 

Caption:  A worker using a helmet

Each factory acceptance test is unique. But you could benefit from learning what real-life FAT testing could include.

Basic Checks

So, the first FAT stage includes these checks:

• Scope. This is where the seller ensures the equipment meets the needed design specifications. They check if everything is in line with the drawings.
• Standards. Some standards to achieve include the NEC (National Electric Code) and NEMA (National Electrical Sellers Association).
• Equipment testing activity. This describes how you did the testing phase. So, you should note the tachometer, vacuum gauge, and other gear used.
• Documents. Each FAT should include relevant documents. Therefore, you usually add these to the protocol’s appendix.

System Skid

Here is what you do during this step:

• GAD and P&ID inspection. You should grab the piping and instrumentation diagram. Check if the components and lines fit the drawings. Furthermore, don’t forget to get the compliance certificates with the general arrangement drawings (GAD).
• An analysis of system skid and components. You need to meet the drawing requirements first. The next step is to confirm the manufacturing quality.

Analysis of the Vessel Nameplate

You’ll need the National Board nameplate for this step. It’s vital to check material info, temperature, and pressure. So, you want to ensure consistency with the P&ID and other requirements. Additionally, don’t forget to include an ASME “U” stamp. 

Controls

Caption: A worker checking the panel

You want to ensure the controls work well. Therefore, start with a panel component analysis. You want to test every operational mode, including the automatic and manual control panel. Check analog displays, light operations, and other relevant areas. Make sure to perform sequences like pressure control, system purge, and leak tests.

Deviations

Deviations are an essential item to include in FAT. So, the mission of every test is for its result to be problem-free and within acceptable ranges. If a failure occurs, you might need retesting for that section. Therefore, don’t forget to add additional documents and comments. If any deviations exist, make sure to point them clearly in the final version.

What Else Is a Part of a FAT Template?

Caption: An engineer with a worker

Apart from the things mentioned above, these items should find their place in the FAT process:

• Check motor data. The test should confirm that the motor is in the right division and class. You should confirm the serial number and model are accurate.
• Pressure tests. If you mount the unit fully, do the lines hold pressure? You should record it at the beginning and finish point and test it for an hour. Therefore, you’ll know the system meets the expectations.
• Vacuum testing. It’s a similar process to pressure testing, except you check if the lines hold vacuum. The process also lasts for an hour and confirms the system meets the standard.
• Punch list. If you performed extra tests, the punch list should note the adjustments made. Furthermore, make sure to include every single detail for an accurate report.
• Testing components. You’ll need water for these tests. Furthermore, you only perform it after completing vacuum analysis. The key component testing starts with agitator rotation. So, you should confirm everything runs smoothly. The next step is checking if the pumps work. So, their task is to ensure water recirculation to and from the reactor.
• Document review. The final step is checking if you included the relevant paperwork in the report.

What You Should Know About FAT Pricing

It’s common practice to include FAT cost considerations in the initial project scope. Therefore, the buyer shouldn’t have to pay extra for a factory acceptance test. On the other hand, the customer must mention what tests they want to run. If you inform the seller at an early point, you can reach an agreement quickly. The seller will know the buyer’s expectations on time.

A factory acceptance test isn’t cheap. On the other hand, it’s vital for the seller. If you don’t do good FATs, the equipment limitations could lead to issues after arriving at the seller’s facility. That could make any repairs more expensive than if you them during the FAT process.

Where Do You Do a Factory Acceptance Test?

Caption: A worker holding his helmet

The seller handles these tests at its facilities. It’s much easier to perform FAT on those premises. So, if the experts notice any errors, they can fix them right away. On the other hand, the customer representative should approve the testing plans. That means the analysis should include anything that the client finds important. It is common practice that experienced staff handles FATs. They check everything from the custom cable assemblies to how the device operates. That ensures the system will work well and deliver consistent machine performance.

The client might ask for an SAT. So, this is a Site Acceptance Test, which confirms optimal gear installation. It demonstrates the equipment design interacts with other peripheral equipment and the general system.

When Should You Do a Factory Acceptance Test?

Most sellers leave at least two weeks before the machine ships. That’s because they want enough time to perform all tests. Depending on the gear, you might perform FAT for customers in a day or a week if you need additional fixes, extending the process further.

Who Should Be There for a Factory Acceptance Test?

There’s no rule as to who should be present. The seller’s staff should perform the tests. So, that means maintenance staff, operators, project managers, and facility engineers should be on location. Furthermore, the client is welcome to visit the factory acceptance test. That ensures they confirm everything works well.

Factory Acceptance Test– Steps to Achieving a Successful FAT

Caption: Factory workers with an engineer

A factory acceptance test means you are close to finishing the project. This is a crucial step that you want to do right and avoid future problems. Here are the steps to performing a successful FAT!

Have a Detailed Test Plan

It all starts with having an excellent plan. The seller usually shows the tests they plan to perform when making an original agreement. Furthermore, include a detailed FAT plan in the contractual obligations. That way, you avoid guesswork and ensure a smoother FAT process. It’s customary for the buyer to pay for initial tests. On the other hand, the sellers handle any subsequent checks if there’s an issue with the machine.

Factory Acceptance Test– Use the Same Materials as the Client

The point of factory acceptance testing is to resemble the actual machine operation at the client’s facility. So, make sure to use the same materials as the customer plans with that equipment. Those will show accurate results and confirm the correct operation. On the other hand, you can use different training materials if you want to show operational flexibility.

Factory Acceptance Test– Call the Operators

Caption: Quality control inspection by a worker

Ask the client who will work on the machine and call them to the testing process. They are the person responsible for running the equipment. So, they are the critical project people. Therefore, it’s best to train them on the spot. You could even get feedback on how to improve the machine’s range of operation. If the technicians feel comfortable, that will ensure the client gets the most out of the equipment. So, it’s all about training the right people for the job.

Factory Acceptance Test– Come Up with a Type of Failures 

It helps to assume what could go wrong during the factory acceptance testing services. Perhaps you have experience from a previous similar project. So, use that to come up with a checklist of what failures could occur. Those could be electronic failures, leaks, etc. Understanding what could go wrong can help focus on those areas and not let an issue surprise you. That makes a failure script vital.

Factory Acceptance Test– Analyze the Replacement Process

No equipment lasts forever. So, components will wear out sooner or later. That’s why you should analyze the replacement process for the main parts subject to defection. You can call customer personnel and practice the changeover procedures. 

Furthermore, use your engineers and other experts. They can simplify and standardize part replacement procedures. 

Factory Acceptance Test– Observe Everything from a Safety Perspective

Caption: A factory worker pushing a button

You can’t afford to miss a single detail related to safety options. Here are some things to consider during the factory acceptance testing procedures:

• Identify potential pitch points and poorly guarded areas.
• Search for sharp edges that could injure an operator.
• Make sure all emergency stops, buttons, and restrictive switches work well. Furthermore, confirm they are easy to reach.

Your FAT should confirm all safety components work well. Additionally, you can identify if there are security functions to add. Don’t forget to do all these in a secure environment.

Factory Acceptance Test– Don’t Rush the Process

High-speed testing shouldn’t be acceptable for the sellers. It’s a big mistake not to dedicate enough time and effort to it. A repair you could have done in a single day could result in an expensive fix that takes weeks down the road. So, make sure to perform every aspect of FAT. If you can’t meet the project schedule, ask the client to change the shipping deadline.

Factory Acceptance Test–Work Together

The buyers and sellers should work together during the entire project. That includes anything related to the FAT process. So, make sure to ask the client the areas where they expect equipment reliability. The customer should be clear about their requirements. They should state the confirmations they wish from a factory acceptance test.

Conclusion

All in all, the factory acceptance test can reveal what the parties need to address before finalizing the shipment. This ensures you cover every detail and keep the project on track. Now, let’s work together. We can talk about the spare parts, required material of construction, maintenance procedures, etc., on the FAT. With your support, we can provide you with high-quality cable assemblies without future problems!

All good things have to end, and that includes the copper wire. You can’t just leave a wire hanging without proper cable termination, which is terrible for the complete and accurate transfer of both analog and digital information signals. Find the best way to terminate the ends, whether it’s a Wire Harness or a Cable Assembly. To learn how wire completing works or how many benefits it has, keep on reading.

1. What’s Wire Terminating?

Wire terminating is everything a user or operator does to the end of a wire. This practice creates a connection. With wire terminating, you can connect wires to devices in any way imaginable. Wire terminating is simple yet tricky to do whether you connect through a connector, a switch, or a terminal.

High-voltage wires.

2. Wire Terminating and Joining Types

Wire terminating is very functional. It is also extremely varied. There are plenty of wire termination types. They all depend on their use (outdoor or indoor), current-voltage, and even type of cable connector.

Passive Termination

Passive wire terminating involves installing all kinds of passive devices. This includes resistors, transformers, capacitors, and even inductors. This will help the wire to handle electricity in a passive way. Besides, it allows future reconnections, as it is not a permanent termination.

Active Termination

On the other hand, there are also active terminations. If users need to keep a steady voltage, operators recommend a different approach. In cases like these, using voltage regulators as wire termination is the best choice. These will give you wonderful results and a highly steady current voltage to work with.

Red voltage regulator.

Forced Perfect Termination

Forced perfect termination is another type of active termination. It is the way to go on single-ended buses, locking the signal between voltage regulators. Also, this translates into better performance over other active wire termination types.

Straight Through joints

There are also wire joints that help users create new connections. This type of joint connects two wires together, extending its length. Operators use covers made of polyurethane to keep joints shut.

Y and T type branch joint

If you want to connect three wires together, a Y and T joint will work nicely. This cover, shaped like a Y or T, keeps the current passage stable and protected. This is ideal to use both outdoor and indoor, as the cover is resistant to water.

Pot End Joints

These wire joints keep live-voltage cables protected when users abandon them. A simple cable cap that shrinks with heat solves the problem. Besides, it offers a safe way to handle live wires when you don’t need them anymore.

Yellow wire nuts.

3. Wire Termination Methods

There are various methods to terminate electrical wires. These methods differ according to the tools operators use or how they perform said methods. 

Man wire soldering.

Soldering

Users commonly prefer soldering wires as termination. When soldering, wires become more flexible, durable, and even resistant to corrosion.

Although soldering is fairly easy to do, it has a catch. Manufacturers recommend only skilled people to solder to avoid accidents of any kind.

Insulation Displacement Connections

If you look for a fast way to terminate wires, IDC is the way to go. You won’t have to deal with striping wires or using chemicals. It’s mostly inexpensive and easy to perform.

Crimping

On the other hand, if you work with lots of wires, crimping offers better results. The terminations are not only mechanically strong but also clean and fast to perform. Operators commonly use wire strippers and the crimp tool to make the wire termination. However, bigger crimping tools are now available for crimping bigger wires, too.

Cable crimping types.

Ultrasonic Welding

This practice is perfect for working with wires covered in plastic. It welds plastics and even some metals like copper, nickel, aluminum, and brass together. Ultrasonic welding creates a metallurgical bond that is strong, flexible and has low resistance.

4. Wire Terminating Applications

As expected, wire terminating has varied uses and electrical applications.

SCSI

SCSI units are a type of active wire terminating. People often use SCSI units as devices to backup and store data. These units use active terminators with voltage regulators to fight current variation. 

SSD hard drive with SCSI unit.

Controller Area Network

Also known as CAN, controller area networks commonly use 120-ohm resistors. CANs allow microcontrollers to communicate with each other without having a computer to host the functions. Manufacturers use controller area networks on elevators, agricultural equipment, and more.

Dummy load

Operators use dummy loads to work in television, radio, and audio-related places. These devices allow operators to try and test electrical loads without endangering the actual infrastructure. Dummy loads often use a resistor. They then immerse it in oil to absorb the heat.

Ethernet Cables 50 Ohm

If you work with computers and data storage units, it is best to use a 50-ohm terminator. It will prevent users from dealing with voltage fluctuation and network connectivity loss. On the other hand, a 50-ohm network cable jack offers safe and reliable connections.

Ethernet coaxial plug.

Antenna network 75 ohm

On the other hand, when it comes to antennas, a 75-ohm wire terminating resistor is the way to go. Also, people use antenna networks for internet connections. However, always look for the right cable for your needs, as this will help you avoid phasing problems due to different impedance levels.

Unibus

Manufacturers and operators also use wire terminating on unibus terminator cards. These units work with 178-ohm resistors when on multi-drop signal lines. However, they use 383-ohm resistors when working on single-drop lines.

MIL-STD-1553 

These kinds of buses use various resistors that connect on both ends of the wire. Doing this will assure you that you won’t experience distortion or intermittent communications failures. Remember that in devices like this, wires may connect to a terminator either from the inside or the outside.

Network tester.

5. Wire Terminating Installation

Splicing requires cutting and jointing wires with care. It’s vital doing it properly to avoid problems. There are some steps you should follow to make it right.

First, prepare the surface. You can choose from End Cut, Wire Slit, Wire Strip, and Cutback according to your need. Clean it, get rid of dust or debris, and make sure it’s water- and oil-free. 

Second, join wire conductors with their connectors. Place splices if needed and join the wires together using the right conductor. For example, aluminum connectors only work with aluminum-bodied connectors. These conductors use an antioxidant paste to eliminate the aluminum oxide coating that insulates both the connector and conductor.

The splicer is checking wires.

Third, reinsulate the wire using tape. Operators and users commonly use black electrical tape to reinsulate the wire. However, linerless splicing and molded rubber splices are better than regular tape. These will prevent air bubbles from forming during the application. On the other hand, molded rubber ones offer flexibility and long-lasting results.

Fourth, it’s time to replace the cable shield. Insulation tapes and rubber splices work best for it. 

Fifth and final, replace the cable jacket with a combination of molded rubber.

Rubber and plastic parts.

6. Wire Terminating Safety

For performing wire terminating safely, it’s important to follow a few simple tips. These will ensure the proper functioning and secure handling of electric wires.

• Use protection boots and gloves.

Boots and gloves will protect users and operators from accidental electrical discharges.

Safety boots and gloves.

Avoid moisture at all costs.

Water and electricity together are a no-no. Make sure all wires are dry and isolated to avoid malfunctions.

Keep everything clean while working.

Get rid of dust, debris, oils, or any other substance that interferes with current conduction or wire insulation.

Always use the right tools for the right wire.

Use the right tools, the right size of splices, and the insulation recommended for every wire. This will avoid problems and delays in the installation process. It’s important to give them what they deserve.

Avoid gaps at the cable’s entrance.

External particles and foreign objects damaged wires. Sealing it properly solves the issue.

Splicer used to work with wires.

Use monitoring sensors regularly.

Online Partial Discharge monitors, also known as OPD monitoring sensors, check how healthy and safe-to-use are the cables and safety boots you’ll use.

Conclusion

Wire terminating ensures the healthy performance of electrical wires, which is especially useful for the automotive industry. However, to terminate power wires, there is a lot to do. If you need more help or guidance on electrical wire, contact us.

Did you notice something is wrong with your engine? You might think you used bad fuel, or your factory fuel pump isn’t working. However, the issue might be with electronics. Especially, the fuel pump wiring harness is an essential component in any vehicle. An optimal setup ensures the engine has a steady supply of gas.

This guide reveals everything about identifying and fixing problems related to fuel pumps. Also, you’ll learn how to secure a high-performance fuel pump with top-quality wire assembly! 

How to Recognize When Your Fuel Problems Are Issues with Electronics

Caption: A mechanic works with car electrics

 If you notice the engine isn’t working well, electronics might be the problem.

Do You Notice a Spark?

The first thing to do is to check for a spark. So, you’ll need a spark plug tester. It’s easy to connect it to a plug lead. Now, a spark will indicate there’s voltage coming from the ignition system. On the other hand, this isn’t a guarantee there aren’t electrical problems. Some issues, such as a bad condenser, will only appear when your engine is operating.

The Importance of Right Timing

Caption: An example of the check engine light

Do you have a distributor system on your engine? If yes, find the crank pulley and place a timing light on its mark. Next, clip an inductive pickup to the first spark plug wire and trigger it. So, look at the advance as it should be approximately 12 degrees at idle.

Newer and import vehicles might have an AI-controlled ignition system. So, the only indicator something is wrong is the Check Engine light. If it’s active and everything else seems alright, engine timing might be bad. That indicates it could be time to replace the engine wiring harness.

Check the Fuel Pump

It’s time to check the fuel pump operation. Most newer cars use an electric pump. But if your vehicle isn’t brand new, the odds are you’ll hear it when turning on the engine. On the other hand, if you don’t hear anything, inspect the fuel pump components.

Here is what to check:

• A Ford fuel pump often comes with a switch that stops the gas supply if a collision happens. So, this switch might recognize a small bump as a collision, which is why this is where to look for first.
• Is your pump drawing current? There shouldn’t be any, so check this, too.
• Finally, inspect the relay and fuse on the system.

Does Engine Get the Gas?

It’s easy to see if the gas comes to a carbureted engine. First, take out the air filter. Next, use the throttle for a second, and you’ll see if there’s gas.

If your car uses an injection system, it’s time to use a fuel gauge. Therefore, connect it to the fuel rail and see if there’s pressure. Additionally, check the manual to find the desired range for your car.

How Problems with Voltage Supply Cause You to Think Your Pump Isn’t Working

Caption: A car fuel pump closeup

Voltage issues are another reason why car owners think their fuel pump harness is the problem. If there’s an electrical issue, you’ll notice a voltage drop in the pump. Therefore, the system might not run at the expected level. If you continue using the car, the pump could fail soon.

You want to look for burned wires or black soot on the harness plugs. The fuel pump module will often have loose terminals. If you notice damage to any parts, make sure to replace them. You want the maximum voltage to your pump, so there should be no damage to the components.

It’s easy to test for voltage drops on the electrical system. Therefore, you’ll quickly find if you need a new affordable fuel pump wiring.

Steps to Replacing a Fuel Pump Wiring Harness

Caption: An automotive fuel pump system

Do you want to replace the wiring harness on fuel pumps? The good news is this can be a DIY product, which means you can do it alone. On the other hand, this is a sensitive process. It’s vital to do everything right for the pump to function well.

Before you start, don’t forget the importance of safety. So, use your gloves and safety goggles during the project. Additionally, it helps to have a fire extinguisher nearby.

Disconnect All Components

All fuel pumps have a negative battery terminal. You should find and disconnect it from the harness. After removing the terminal, it should be easy to take out the actual harness. Your system probably uses plastic conduits and tape as protection. So, make sure to remove it first and then take out the harness. 

Wire Everything

Use a table in your garage in any other location. It’s important to have enough space for wiring your new harness. First, check if you use the same wiring diagram. If yes, you can even photograph it before removing out from the car. That way, you’ll know how to handle the connections.

It’s common that the new wiring is different. So, check the diagram you received with the new setup. It will help you to understand how to wire the components.

Cut the Wires

The next step is to cut the wires to the desired length. Now, you want to shorten the wires close to the electrical connectors. So, the experts recommend cutting them about two inches away to leave some room. Next, stagger other cuts to a similar length. Finally, strip the wires.

Each cable in your wiring kit should come with a wire connector. So, your goal is to crimp the car wiring to the new setup. On the other hand, make sure that the electrical connector crimp is free from any insulation. Additionally, you can use a heat gun. It ensures a secure connection by shrinking the insulation.

Install the Harness

Caption: Multicolored wires in the engine control unit of the car

The crucial tip is that there shouldn’t be any fuel until you install the wiring kit. While installing the seals, make sure they are tight and offer adequate weather resistance. Finally, use tape to keep the wires in position and apply the plastic conduit. So, this should ensure fuel pumps function properly. The only remaining thing is to start your car and see if everything is working well.

Why You Should Use a Fuel Pump Wiring Harness by Cloom

Caption: Maximize the performance of your car with a fuel pump wiring harness

Is it time for a new fuel pump wire harness? You want the best combination of price and quality. At Cloom, we design super automotive wiring that secures your car’s top performance.

Here are the main reasons why you should trust Cloomm and its products:

• Our fuel pump wiring harness complies with OEM and other relevant standards.
• The installation is simple and hassle-free.
• Our experts listen to your specific needs and design a custom assembly.
• We only use top-quality materials for our wiring harnesses.
• You receive a finished product in the shortest possible timeframe.

Cloom delivers wiring harnesses for custom configurations of fuel system setups. Our team has years of experience, and our designs are long-lasting and durable.

Conclusion

It’s vital that your fuel pump wiring harness works well to secure stable car performance. If you have any questions regarding vehicle wiring, don’t hesitate to contact us! We can solve different issues that might occur and teach you how to apply a new wiring kit. 

Today, forklifts usually use a forklift battery to supply their motive power, because it is environmentally friendly.  Also, they can avoid dangerous fumes, such as carbon monoxide. Choosing the proper ones keeps your forklift in production during every shift. Also, charging properly makes a long life for your battery. 

However, many laypeople don’t realize how easy it is to make severe mistakes when dealing with a forklift battery. Luckily, the following information will be beneficial to you.

1. Forklift Battery Types

Here are three forklift battery types people use the most. Each one depends on the forklift’s use.

(Render of an industrial forklift)

Lead-Acid

Operators use these forklift batteries the most, as they are easy to use. They are liquid-filled wet cell batteries in a big shape with a removable top. Through the chemical reaction of lead plates and sulfuric acid, it generates electricity. 

Also, with the right maintenance, they last over 5 years. Every battery manufacturer recommends users do regular maintenance. This ensures accurate battery voltage and electrolyte levels to grant top battery performance.

Lithium-Ion

Although expensive, lithium-ion batteries have a long list of benefits in comparison to others.  For example, one of the most popular chemistries they have is Lithium Iron Phosphate (LFP),  which is more energy-dense than lead-acid.  
Instead of a removable top, the cells are sealed shut. Even there is no water maintenance, they can work properly.

(Rechargeable electric forklift)

Absorbed Glass Mat (AGM) Forklift Batteries

Although this type of battery is not as common as lead-acid or lithium-ion batteries, AGM batteries benefit a lot. The glass mat inside the battery passes electrolytes between plates. By suspending electrolytes in this dry state, maintenance requirements decrease. This avoids any accidental acid spillage in case of a cracked battery case. 

(Forklift battery ready for replacement)

On the downside, their performance lowers when charged improperly. Manufacturers recommend discharging the battery to no less than 50% on each use to ensure top performance.

2. Forklift Battery Price

Buying a forklift battery is an investment. When considering battery prices, you should consider the initial buyout price and the maintenance costs over a certain period. This makes the lithium-ion battery a better option.

Lead-acid batteries last about 5 hours with one single charge. However, it needs up to 8 hours to fully charge and an extra 8 hours to cool down. With proper maintenance, these will last up to 1500 charging cycles.

(Several forklifts parked inline)

On the other hand, lithium-ion batteries last over 7 hours with a single-use. They only need up to 2 hours to charge completely and need no cool-down. In addition, with proper maintenance, lithium-ion batteries last up to 3000 cycles.

Lithium-ion forklift batteries are almost double the price of lead-acid ones. However, over the course of 5 years of use, using lithium-ion ones grants you savings of over $20K per battery. Just think of the big picture here, the more lithium-ion forklift batteries you own, the more savings you’ll have.

(Man in forklift)

3. Forklift Battery Sizes

Whether they are big or small, light or heavy, forklift battery sizes vary depending on the vehicle they will supply the power to. 

24-volt forklift battery

It is perfect for anything small like electric walkie pallet jacks, end riders, walkie stackers, or center riders.

36-volt forklift battery

When it comes to narrow aisle forklifts or any other mid-sized vehicle, a 36-volt battery is a way to go. 

(Industrial battery)

48-volt forklift battery

If you work with counterbalanced electric forklifts or any other large electric lifting vehicle, a 48-volt battery will do the trick.

80-volt forklift battery

They work with any extra-large, heavy-duty vehicle.

4. Forklift Battery’s Common Risks

As forklift batteries are bigger than regular car or truck batteries, the risks and consequences increase exponentially. However, lead-acid batteries present the most common risks.

(Battery spilling warning signal)

Dangerous Gases

Lead-acid industrial batteries emit dangerous gases when overcharged. This includes hydrogen, hydrogen sulfide, and sulfur dioxide. It’s important to ventilate the charging room at all times. Or at least,  install sensors to measure the concentration to avoid explosion.

Overheating

While charging, a lead-acid forklift battery raises its temperature after peaking charge for too long. It’s crucial to control the temperature of the charging station, the room, and the battery itself to prevent accidents.

(Rechargeable forklift battery with the electric connector on top)

Spills

Battery acid causes chemical burns, hindering workers’ overall job performance. The same thing happens when it comes to slips and falls. Lead-acid batteries need weekly watering. For this, it is recommended to have a chemical washing station on the premises to deal with battery acid spillage and burns. 

Old, Corroded Batteries

A new lead-acid forklift battery presents no safety hazard to operators. On the contrary, an old and corroded battery multiplies the risks.

(Corrosion on battery cables)

Other risks of using any of these forklift batteries include physical injuries to workers. This includes lifting battery weight, moving, charging the batteries, and injuries if a battery falls on anyone. 

5. Forklift Battery Watering System 

As mentioned above, lead-acid batteries need constant, regular, and much-needed watering to function the right way while lithium-ion ones need no watering at all. 

(Operator checking water levels on forklift battery)

To make it work, it’s crucial to only water the battery once it’s charged and completely cooled down. Also, be extremely cautious not to overfill it to avoid spillage. Leave space inside for the fluids to expand and use water that’s level 5 to 7pH in the acidity scale. In addition, it’s vital to water the forklift batteries every 9 or 10 charging cycles to avoid the exposition of the lead plates’ tops.

6. Forklift Battery Charging

Proper battery charging leads to extended battery life. Whether for lead-acid or lithium-ion, there are some factors you should consider before starting the charging cycle on your forklift battery.

(Forklift batteries on charging station)

Charging Time

While lead-acid batteries take 8 hours to charge up to 100%, lithium-ion ones take only 1 to 2 hours per charge cycle to do so.

Cool-Down Time

When it comes to cool-down time, lithium-ion batteries take the lead by far. Lead-acid batteries have to cool down for another 8 hours before using them. Lithium-ion forklift batteries don’t need cool-down time. They can be opportunity-charged and don’t need to be fully charged to use it.

Charging Method

The charging method is very different. Lead-acid batteries need to charge in a separate charging room where they remain until hitting 100%.On the other hand,  lithium-ion batteries charge by plugging the cord directly into the wall without removing it from the vehicle.

(Forklift batteries charging on charging station)

7. Forklift Battery Maintenance

Electric forklift batteries maintenance is easier than your think. Yet, it should be regular, consistent, and thoroughly done. There are some major tips to follow.

Check Water Levels

Check the electrolyte level every 5 to 10 charging cycles, and only once the battery is completely cool. In addition, be aware of white crystal formation on the plates. If this occurs, it’s time to call an experienced engineer to solve the issue.

Clean Batteries Regularly

Clean the top of the battery with warm water or battery cleaner to avoid corrosion.

(Battery operator handling a battery while using protective gear)

Use Protective Gear

Use protective gear when handling the battery. This includes face shields, protection glasses, and steel-toe shoes, among others. Also, remove the jewelry and all metallic accessories while handling battery acid.

8. Signs of Forklift Battery Repair or Replace

Some signs let users know when or if their forklift battery needs repair or replacement.e signs that let users know when or if their forklift batteries need repair or replacement. 

Sulfation or Corrosion

Corrosion appears as a sign of battery age, and sulfation shows due to over-or undercharging. But no matter what happens, it’s best to replace it.

(Sulfated forklift battery)

Constant Charging

Constant charging translates to constant stopping while working, wasting your time and money overall.

Smoke while Using or Charging

If the battery releases smoke while charging or using, it means gasses inside our building and is an explosion hazard. 

Odd or Rotten Smell while Using

If an odd or rotten egg smell is present while using the forklift, it means the battery has corrosion inside it. 

(Disgusted man covering his nose)

Conclusion

Knowing how to choose the correct battery cell for your business’ needs can make or break your entire business plan. Hopefully, you now know how to do it right. If you are looking for any type of battery cable assembly for your forklift, contact us.

Over the past couple of years, going green has been emphasized.

Renewable energy continues to be a mainstay among residential and commercial properties.

Among them is solar power, given its abundance and easy installation. 

Cloom provides custom cable and wiring harness technology for your property.

Part of our service offering includes solar cable.

As you read along, you will discover what they are, their applications, and how to procure them through Cloom.

What are Solar Cables?

A solar cable is a conductor that connects your solar panels to the rest of the photovoltaic system.

As the sun shines upon the panels, the resulting energy transfers to the battery pack and an inverter changes it to the alternating current that home appliances use. 

Furthermore, these flexible cables resist harsh environments such as exposure to ultraviolet rays, weather changes, and extreme temperatures.

It also includes insulation that can withstand the varying voltage classes of the equipment it utilizes.

Finally, your solar cable’s performance requirements adhere to the national and local electrical codes regulating your area’s electrical installations.

In addition, the rules that govern grounding regarding electric shock and lighting protection vary depending on your jurisdiction. 

The Solar Energy Cable in Solar Systems – Transportation of Electrical Energy

Electrical power systems use several cables and wires to transport the electricity from the generation unit to where you will use it.

The below are responsible for ensuring you get the necessary power for your appliances from your solar system.

Solar wire

A solar wire is a single conductor that sends power from the source to the battery pack.

Solar cable

A solar cable is a collection of several conductors, all wrapped in an insulation jacket that is sunlight resistant.

Depending on the voltage, you can get them in varying diameters.

Correctly Sizing the Solar Cables and Wires in a Solar System

Overheating and energy loss are some dangers of using the incorrect cable size.

Furthermore, you are at great risk of fire when you use the wrong cable for your installation.

As such, always check the AWG standards to avoid code violations.

In addition, you need to select the proper wiring and cable sizes to connect the below components.

Diagram for a solar power system

Inverter

Solar electric power is generated in DC. An inverter changes it to alternating current (AC), the norm for most home appliances.

Solar panels

Solar panels on residential houses.

This changes the sun’s energy into DC electricity stored in your solar power batteries.

Charge controller

These control the amount of power stored in the batteries to stop them from overcharging.

Batteries

They supply power to your house whenever the sun is unavailable.

When selecting the right wire size for your solar power system, keep the following factors in mind:

• The amount of power that your solar panel generates. For example, a single panel can make 10 to 300 watts. Most homes feature single panels that generate 100 watts of power.
• Therefore, match your wire to the generating capacity of your solar panel.
• The larger the current, the bigger the wire you need.
• Consider the distance between your panel and the battery packs.
• For example, you will need a larger PV wire to fit in with the distance between your solar panels, combiner boxes, and batteries.
• Finally, AWG tables are suitable for solar power systems’ single, solid, and ground wires.
• Additionally, the cross-sectional area of equal solid conductors determines the measurements for stranded wires.
• Since stranded wires contain small gaps within the conductors, their overall diameter is more significant than a solid wire of a similar AWG.

Solar Wire Types for Solar PV Installations

Below are the wires you can use for your solar power system.

Aluminum or Copper

The Aluminum wires for Solar Street lights.

Aluminum wires are standard in larger gauges as compared to copper.

As such, you cannot use them for your in-house wiring connections. Furthermore, aluminum tends to weaken from bending.

Therefore, it is only ideal for overhead service entrances, direct burial installations, and commercial operations.

Copper wires offer you better conductivity than aluminum of equal AWG size.

Consequently, it works better for internal connections in your residential or commercial property.

For example, the wiring of a standard residential property will use copper for the connections between the panels, combiner boxes, and battery packs.

Solid or Stranded

A solar cable is available either as a solid or stranded solar cable.

Additionally, a stranded solar connector cable features a collection of many small wires allowing it to be flexible.

Furthermore, they offer more conductivity since there is more wire surface than a solid solar connector cable.

Insulation

A proper solar connector cable portfolio includes conductors resistant to moisture, heat, UV light, and chemicals.

As such, you will find them using either of the below insulation materials as per the National Electrical Code.

Color

Solar wires use color codes for insulation to show their usage and function.

Below is a table showing the applicable color codes.

Can I Customize Solar Cables At Cloom?

Cloom can supply you with the following array of cables:

What sizes do Solar Cables come in?

• THHN wire is ideal for general-purpose buildings.
• You can have it in sizes ranging from 1000 MCM to 14 AWG.
• USE-2 Solar wire that is available from 4/0 to 14 AWG
•  UL Rated Photovoltaic wire available from 250 to 18 AWG.

What types of solar panel connectors are available?

Cloom has the following solar connector types:    

• MC4 Locking connectors
• SOLARLOK® Solar connector
• MC3 Non-locking connector

What types of solar cables are available?

You can consult for the following solar cables.

Battery Interconnect cables

Battery interconnects cables.

Our battery interconnects cables come with 10 mm terminal lugs.

Additionally, these are available in either 2/0 or 4/0 cables. Furthermore, ensure that you select interconnect cables of the proper length.

You can do this by placing the battery bank and measuring the distance between the terminals you wish to connect.

Battery to inverter cables

These are available in either 2/0, 4/0, or 6 AWG. Additionally, we use special crimping for each lug for the cables.

Furthermore, all the battery cable is per UL listing and NEC Designations.

Tray Cables (Charge controller to the battery)

Our tray cables are available in either 8ft or 16 ft. In addition, the tray cables have an AWG size of 8 or 10.

Furthermore, they offer UV resistance and can produce optimum power output in high-temperature photovoltaic systems.

Solar panel extension cables (solar panel to the controller)

Cloom offers a variety of AWG solar panel extension cables ranging from 10 to 14 AWG lengths from 6 ft to 50 ft.

Additionally, they feature double insulation suitable for electrical installations prone to extreme temperature ranges.

Furthermore, each AWG solar extension cable has a male and female connector and a solar panel adaptor kit tool for easy installation.

Adaptor cables/Adaptor Kits 

The solar panel to charge controller adaptor kit is available in 10 or 12 AWG.

Additionally, we offer a variety of solar panel extension cables from sizes ranging between 10 to 14 AWG at lengths from 6 ft to 50 ft.

Additionally, they feature double insulation suitable for electrical installations prone to extreme temperature ranges.

Furthermore, each AWG solar extension cable has a male and female connector and a solar panel adaptor kit tool for easy installation.

Conclusion

Your solar installation assembly requires a variety of wires to ensure that it functions at its optimum level.

Consequently, the type, size, and length of a wire depend on the kind of system you use. 

Therefore, you need a reliable partner to support you in identifying what is suitable for you.

Always seek a consult from Cloom to get the best solar cable and wire solutions for all your photovoltaic systems.

General Motors is the company that makes the entire family of LS engines. You’ll find budget-friendly options with tempting prices. Some engines, such as LS3 and LS7, are costlier. On the other hand, they justify the money spent on their performance.  Do you need a modern LS engine swap? If yes, you might worry about how to deal with the LS Swap wiring harness! Now, don’t hesitate to start reading and become an expert on this swap! This guide will discover everything you should know.

What LS Engine Swap Customizations Exist?

If you secure a clean installation, the LS engine will perform flawlessly. Therefore, check the potential customizations for LS engine swaps!

Motor Mounts

You’ll need an adapter plate to connect the motors. Put them on the engine block to tie it to the cross member. Additionally, you can pick between plates with stock location and adjustable models. You might need to move the engine from the original position. So, make sure to plan any changes carefully.

Computer and Wiring Systems

You can rewire the existing harness systems. Additionally, you can use custom setups or standalone harnesses. All these choices work well. Therefore, it depends on your skills. Enthusiasts might go with rewiring, while the additional options are better for beginners. You can find many automotive wiring harnesses available. 

Transmissions

Caption: A closeup look at the power transmission gears box

The market offers a wide choice of units. Therefore, the first step is to choose between two types:

• Automatic transmissions. You can go with 4L60E, which has great value for money. On the other hand, 700R, TH400, and TH350 need a flexplate adapter.
• Manual transmissions. The experts suggest TR6060 and T56. They are versatile and easy to install. On the other hand, these aftermarket transmissions require extra work.

Fuel Systems

If you are a Chevy hardcore fan, you need a pressure regulator. Furthermore, there should be optimal flow in the fuel pump. That implies you should use fuel injectors, so make sure to install that option. It would help if you also had an intake pump. Thanks to that, you’ll avoid problems with gas starvation when you have little fuel in the tank.

Gauges

If you want info about the events in your car, you need gauges. Therefore, pick a suitable unit. You can pick between two types:

• Mechanical gauges. You can put them on the engine block. Therefore, all it takes is to find an adapter.
• Electronic gauges. These are even easier to install. So, they are suitable if you don’t have advanced knowledge about gauges.

Exhaust Systems

Caption: An exhaust system in a modern racing vehicle

You start by checking the exhaust system on your actual engine. The market offers many additional options for a new system. On the other hand, each unit you select will need length adjustment. The experts suggest going with headers. That’s because they are better at getting more horsepower than factory intake manifold connections. The downside is they might be loud.

Carb Conversions

You can consider a carbureted setup. So, it requires a carburetor for the LS engine. Fortunately, you can pick from many models. If you pick a carb, you won’t need some wiring and knock sensors. On the other hand, get a control box. It allows running the ignition system.

Steam Tubes

The purpose of these parts is to stop overheating in the engine heads. Therefore, you want a perfect connection to allow air to leave safely. The air usually goes to a radiator or water pumps housing and spacers. Additionally, most configurations need uncapped steam tubes.

How to Run an LS Engine?

Caption: A car engine closeup

You have multiple options for running LS engines. Therefore, it’s all about finding one that fits your preferences. 

Use a Carburetor

These components have jets. Therefore, they can boost the gas and move it to combustion chambers. The carburetor has a venture that pulls air. The amount sucked will affect how much fuel goes through the jets. 

The problem is that there’s no option to assess the ratio of fuel and air for each cylinder. So, that increases the emissions. That is why carburetors aren’t the most common option these days. On the other hand, this variant is more affordable and easier to install. Furthermore, it can last longer than EFI, which is why professional drivers prefer it.

EFI – Electronic Fuel Injections

Caption: An engine fuel injection nozzle

Do you want your engines to provide the best performance? If yes, EFI is the right way to go. Fuel injection involves using an injector to introduce fuel to the engine with internal combustion. As for the LS swap wiring harness, you have three options.

Retrofit the Stock Harness

This option demands advanced knowledge about wiring and your factory harness. Therefore, the experts don’t recommend it if you don’t have previous experience. If you still decide on this upgrade, make sure to understand the process first. You don’t want to enter the project without the required equipment and knowledge. That often leads to failure. Furthermore, you might risk. 

Standalone Wiring Harness

A standalone wiring harness is an option that only offers basic coverage. Therefore, you can use it for engine control and nothing else. If you compare it to a factory unit, you’ll notice its compact size. Furthermore, a standalone wiring harness comes with fewer connections. On the other hand, that means it should run fuel management or cruise control.

The box installation is simple but requires patience. If you know how many connections you need, secure enough time. That way, you’ll execute everything flawlessly when setting the standalone wiring harness.

Custom Harness at Cloom

Caption: Manufacturing wiring harnesses

Do you know your exact harness requirements? If yes, you can contact Cloom and place an order. And if you aren’t sure about the best setup for your application, Cloom experts can help. Our team has advanced knowledge and extensive experience with LS wiring harnesses. Therefore, we are your perfect partner when choosing the desired assembly. So, don’t hesitate to contact us today with your specific harness requests! We’ll also guarantee the shortest delivery times.

How to：4 wire LS Swap Wiring Harness conversion 

Caption: Assembly a wire harness with connector housing and terminal

Are you looking to convert a 4-wire LS wiring harness? If yes, you should get enough time for automotive projects. It’s sensitive work, and you want to focus on it. On the other hand, it’s not harder than a 5^th-grade science fair project. 

Here are the steps to follow:

1. Make a photo of the current installation. You can make as many images as you want. Furthermore, use wires with labels and masking tape to figure out the difference between connections.
2. Remove everything from the car. A socket wrench is suitable for taking out terminal clamps. Additionally, take off the negative ones first. Finally, get the harness out of the car.
3. Apply the converter. Your conversion kit should come with a manual. Therefore, you should follow it to install the part.
4. Place the new setup. Make sure you get each wire into the right socket. Furthermore, double-check because you want everything to work.

What Accessories Does the Adaptation Require?

Wiring up the engine is the first step. Next, you want to connect the extras. Here is a list of major accessories you could need!

Gauges

The manufacturers route all gauges through the center console. On the other hand, that wasn’t the case with earlier models. That’s why retrofitting new gauges might need a lot of effort. Therefore, you should ensure compatibility. That includes finding suitable tachometers and speedometers.

Tachometers

Caption: A vector illustration of a tachometer

This part is essentially a gauge. It shows the engine’s RPM, which stands for revolutions per minute. Therefore, they are useful in cars with a manual transmission. Are you a driver that takes the car’s potential to its fullest? If yes, you’ll need to learn if you are overworking the engine.

You might need an adapter to set an old stock tachometer. That’s because it doesn’t have the same signal modulation. Therefore, you might need a module. If you do, make sure it fits your product.

Speedometer

Do you have automatic transmission? If yes, you’ll do with an electronic aftermarket speedometer. The computer sends its signals via the VSS system. You can use a compatible cable-driven speedometer for a transmission drive by cable. Some units require an adapter, which requires extra work.

Oil-Sending Part

This is another area that could need adaptation. Therefore, you should find a place to set it. You can put it on the pan on top of the filter. 

The available bypass fitting options include:

• Dome top
• Tapped and drilled
• Blank boss

Chevy hardcore fans know that 2005-up engines have a dome cap. The models from 1998 to 2002 have a boss, and the earlier ones have a drilled and tapped factory thread.

Drive-by-Wire Systems

This part confuses many users. If your modern engine has this system, it has a unique throttle body and pedal. Furthermore, you might find a TAC module. The problem is you can’t swap these parts. The drive-by-wire should have the same items to work. You can only pick a different module, and that’s only if you adjust the computer, too.

You’ll find Corvettes had a TAC module separated from the pedal until 2004. GM applied a drive-by-wire pedal in 2005. Therefore, the swap only needs a throttle body and pedal. You’ll find SSR trucks using a TAC module mixed with the DBW pedal. On the other hand, a 2007 Trailblazer only has a pedal.

Users will need conversion engines for adjustable pedal options on Vortec-powered trucks. The driver can set the pedal based on their height. The problem is that GM changed truck settings a lot over time. Therefore, checking things with an expert is vital.

Conclusion

That rounds up the basics of the LS swap wiring harness. As you can see, a perfect connection guarantees saving money on guess and a better experience when driving. So, if you have any questions or need assistance with cable assemblies, feel free to contact us today!