EasyPower User Manual

EP48460CWT-CB4-E (1003220) EP48460CWT-CB3-E (1003500) EP48310CWT-CB3-E (1003200)

www.alelion.com

2016-06-09, 1004069-001 2

Contents

General.................................................................................................................... 3 Safety ...................................................................................................................... 4 Overview ................................................................................................................. 5 Operation ................................................................................................................ 7 Troubleshooting .................................................................................................... 10 Recycling ............................................................................................................... 11 Repair .................................................................................................................... 11 Appendix ............................................................................................................... 12 Declaration of Conformity ..................................................................................... 12 Material Safety Data Sheet ................................................................................... 13 Battery Markings ................................................................................................... 16

Basic Battery Data

Product no: EP48460CWT-CB4-E (1003220) Battery Type: Li-Ion (NMC) Nominal Voltage: 51.8 V Nominal Capacity: 448 Ah Energy: 23 kWh Usage Temperature Range: 0°C to +45°C (ideally +15°C to +25°C) Storage Temperature: -30°C to +45°C (ideally +15°C till +25°C) Weight: 994 kg ±5% Usage: 48 V DC systems

Product no: EP48460CWT-CB3-E (1003500) Battery Type: Li-Ion (NMC) Nominal Voltage: 51.8 V Nominal Capacity: 448 Ah Energy: 23 kWh Usage Temperature Range: 0°C to +45°C (ideally +15°C to +25°C) Storage Temperature: -30°C to +45°C (ideally +15°C to +25°C) Weight: 856 kg ±5% Usage: 48 V DC systems

Product no: EP48310CWT-CB3-E (1003200) Battery Type: Li-Ion (NMC) Nominal Voltage: 51.8 V Nominal Capacity: 308 Ah Energy: 16 kWh Usage Temperature Range: 0°C to +45°C (ideally 15°C to +25°C) Storage Temperature: -30°C to +45°C (ideally 15°C to +25°C) Weight: 856 kg ±5% Usage: 48 V DC systems

3 2016-06-09, 1004069-001

EasyPower Lithium Ion Battery

User Manual Read this User Manual carefully before you use the battery.

Keep the instruction for future reference and also keep the user manual available for the user of the battery.

Installation is only allowed to be done by authorized personnel.

General

The EasyPower battery consists of lithium-ion type cells and a BMS (Battery Management System) providing onboard intelligence for charging, discharging and supervision. It is intended for installation in electric lift trucks and material handling equipment for indoor use. This product presents a number of advantages over traditional lead-acid batteries, please read the instructions carefully and make sure to follow them. This will ensure that you get maximum benefit of your EasyPower battery. The EasyPower battery has its own steel enclosure that when it is mounted in the outer steel tray that includes ballast, is fulfilling the lift truck manufactures recommendations. The EasyPower battery is designed for a specific lift truck model and cannot and should not be used anywhere else. A designated charger shall be used for charging, it is controlled by the EasyPower battery via the CAN-interface. The capacity demand when you use a lithium-ion battery is as a rule lower than a corresponding lead-acid battery. This is due to lower losses during use, better lifetime properties and the possibility to charge faster and more often. For more information consult the technical manual or contact your lift truck service organization or the lift truck manufacturer or the importer in your country. For more information about the advantages of the EasyPower battery please visit: www.alelion.com

2016-06-09, 1004069-001 4

Safety As this EasyPower battery is of a lithium-ion type and is used in an environment where there is a potential risk of confusion with a lead-acid battery, we recommend that all personnel are informed about the difference of the two systems. This will prevent unsafe handling and also ensure that you get maximum benefit from the EasyPower battery.

The EasyPower batteries are very safe under normal operation and the onboard intelligence is designed to prevent hazardous situation even if the EasyPower battery is used outside normal parameters. Please observe following warnings before using the battery:

o The Easy Power battery should only be used in the lift truck it is intended for, the weight and voltage are stated on the label, and shall be consistent with the requirements by the lift truck manufacturer. Deviations could damage both the lift truck and cause injury to personnel.

o Do not use the EasyPower battery if it is damaged. Do not touch damaged parts and contact service personnel.

o Avoid creating short circuit between the external battery terminals and its

contacts. A short circuit can cause fire and injuries to personnel.

o In case of fire, flames or smoke from the EasyPower battery; While driving: stop, turn off lift truck and leave the area. While charging: stop the charger or remove the charger cable and leave the area.

Call for assistance from the fire department and follow the local fire hazard protocols. A small fire can be controlled with CO2 fire extinguisher, but a major fire will require large amount of water.

o The EasyPower battery shall only be connected to a designated charger that is

configured for charging the EasyPower battery. Do not use any other charger, as this could risk harming personnel or damage the EasyPower battery.

o Only use the supplied cables. If the cables are damaged, replacement cables shall

be ordered from the lift truck supplier or its representatives.

o Installation or removal should only be performed by authorized personnel.

o Do not climb or stand on top of the EasyPower battery.

o Do not open the EasyPower battery and access the inside.

o Do not place foreign objects in or on the battery tray.

5 2016-06-09, 1004069-001

Overview (topside)

1. Lift truck negative (-) terminal 2. Lift truck communication interface (CAN-bus contact) 3. Charger interface (on the side wall) 4. Lift truck positive (+) terminal 5. Battery Indicator 6. Label with key data

Connection to battery terminals shall be made by M10x20-screws with a torque of 24Nm.

Lifting Use the proper lift holes and lift equipment that exerts vertical load on the fixing points.

55

2 2 2

3 3

2

4

2 1

2 2 2 2

6 4 2 2 2

2

5

2016-06-09, 1004069-001 6

Labels

Product code; identifies the battery type

EC 62620

Product

Electrical and technical data

Product number; specifies the exact build

Customers own product number

Nominal weight; with and w/o ballast

Symbols; see back page for more info

Warning label; yellow with black text

Cell designation according to IEC 62620

Serial number; unique for each battery

7 2016-06-09, 1004069-001

Operation The Easy Power battery has several benefits compared to a traditional lead-acid battery; noticeable for the operator is the use of separate connection for charging. To eliminate the risk of ignoring that the charger is connected and drive away, the onboard intelligence will not allow the lift truck to be moved during charging.

There is also a data communication connector that attaches the battery to the lift truck via a digital interface. This provides communication about battery status such as SOC (State Of Charge). The charging is easy and fast, and you can charge anytime without compromising the life expectancy as with a traditional battery. There is never any risk for overcharging and several short charging pauses over a work day can replace a longer charging session, this is the most effective when using a high powered charger.

Battery Indications The EasyPower battery is integrated with the lift truck and its status can be read using the

ordinary instrumentation. For more information about how and what battery specific data

that is indicated (State Of Charge, fault codes, etc.) in the lift truck instrumentation, please

refer to the lift truck user manual.

There is an onboard LED-indicator that indicates the EasyPower battery BMS status. The green LED indicator is located on top of the EasyPower battery. A quick blink once each second indicates that the EasyPower battery CAN communication is active and the battery terminals can be activated if this is not prevented by a fault condition. A blink one (1) to two (2) times every 60 seconds indicates that the EasyPower battery is in protect mode*, there is no CAN communication and the battery terminals cannot be activated. *(See the subsection Troubleshooting/Protect Mode)

2016-06-09, 1004069-001 8

Charging The Easy Power battery utilizes an external charger for charging, the charging interface also has a CAN-communication link that ensures optimal charging control. For more detailed information regarding charging and the functionality such as indications and behaviors of the charger refer to the chargers user manual. The following chargers are recommended to be used together with the EasyPower batteries covered by this manual:

o Micropower access MA4551-3616 165A (1004073) o Micropower access MA4721-3616 260A (1004074)

Connect the charger cable connection to the Easy Power battery charging contact. Make sure the charger is ready for charging and the charging of the EasyPower battery will start automatically when communication is established. During the connection the external poles are deactivated. When you need to use the system again, stop the charger and remove and the charger cable from the Easy Power battery. The EasyPower battery is perfect for opportunity charging, make use of your natural breaks and periods when lift truck is idle. The EasyPower battery is not damaged by charging little and often. The charging time will depend of the output power of the charger and the nominal battery capacity and the current SOC (State Of Charge) as well as the internal temperature. Maximum charging current that will be utilized by the battery, regardless of the output capacity of the charger, are 300A or 1C if the battery capacity is smaller than 300Ah. Example showing estimated bulk charging time:

0 to 99% SOC: Charger output: 165A 260A EP48460CWT-CB4-E 2,5h 1,5h EP48460CWT-CB3-E 2,5h 1,5h EP48310CWT-CB3-E 1,5h 1h

The charging is recommended to be done in a temperature within +5˚C to +30˚C. Outside this temperature range, the charging current will be limited, and the charging will take longer time. We recommend that you keep the EasyPower battery connected to the charger when not in use.

9 2016-06-09, 1004069-001

Storage Please note as all batteries the EasyPower battery has a certain self-discharge, this is mainly due to power consumption of the inbuilt security system. Never store an EasyPower battery that indicates or warns that the SOC is low, it should be charged at first given opportunity. Store less than four (4) weeks; no special consideration needed, the battery should not risk going to protect* due to self-discharge during this timeframe. Store more than four (4) weeks; charge until full before the lift truck / EasyPower battery is put in to storage. Follow this to avoid ending up in protect* mode due to the self-discharge earlier then needed. Before it is put back in to use, charge again if needed. *(See the subsection Troubleshooting/Protect Mode) Control a stored EasyPower battery at least every sixth (6) month and charge if SOC <50%.

Driving Always use lift truck according to the manufacturer’s instructions. Normal operation should

not be any different for the operator until the EasyPower battery is almost empty. This will

be communicated to the lift truck and it will initiate various limitation actions. This can be as

an example; limited acceleration and/or lower lifting speed. When this occurs you are

driving on the last reserve and therefore should stop working and recharge your Easy Power

Battery.

For more specific information regarding the lift truck limitations when battery capacity

reaches the end, please refer to lift truck user manual.

Maintenance Maintenance is only allowed to do be done by instructed personnel that have knowledge of batteries with high energy content.

Once a week: o Control that the charging connections are undamaged. o Clean if needed, the EasyPower battery shall only be wiped off when cleaning.

Never use flowing water or high pressure cleaning. Once a month: o Let the charger be connected to the EasyPower battery until it indicates battery

fully charged, at least once a month to keep it balanced*.

*(After a while with incomplete charging and loading cycles the need for balancing might occur. This will ensure that all cells are fully charged and that you have all the capacity at your disposal. The balancing is automatic and is done if needed with help of the charger, at the end of the charging cycle.)

Remaining maintenance shall be done by service personnel at occasions that follows ordinary service schedule for the lift truck.

2016-06-09, 1004069-001 10

Troubleshooting

Protect Mode To protect the user and the hardware connected as well as the EasyPower battery; some situations can trigger the EasyPower battery to go in to a protect mode. It will then disconnect the DC output terminals. This can be an indication of a problem, but can also be triggered by usage outside the normal parameters, or as a last measure to avoid harmful deep discharge when the battery is close to being fully discharged. If this is due to a fault in the lift truck it will also be indicated by the lift truck instrumentation, please refer to lift truck user manual. To bring the EasyPower battery out of the protect mode, it should be connected to an active charger or as a second choice if no charger is available, disconnect the cable connector from the EasyPower battery CAN -bus connector and reconnect. This will if possible reset the EasyPower battery and bring it out of the protect mode, if this is not prevented by a serious fault condition.

Faultfinding

If the EasyPower Battery shuts down during use it can be caused by: o Damaged cables o Broken fuse o Too low cell voltage o Too high or low battery/cell temperature

If this happens make a visual inspection of the EasyPower battery connections, without removing it from lift truck. Is there any suspicion regarding damaged cables, contact service personnel. If no damaged cables can be detected visually, proceed with next step. Put the EasyPower battery on charge in an indoor environment +5°C to +30°C. Wait at least for one (1h) hour and try to use the EasyPower battery again. If the EasyPower battery does not start or start and shut down again within one or two minutes (1-2 min), contact service personnel. If the EasyPower battery cannot be charged it can be caused by:

o Damaged cables o Too high or low battery/cell temperature o The charger is faulty

If this happens make a visual inspection of the EasyPower battery connections, without removing it from the lift truck. Is there any suspicion regarding damaged cables, contact service personnel. If no damaged cables can be detected visually, proceed with next step. Try another charger, if it still refuses to charge, proceed with next step.

11 2016-06-09, 1004069-001

Remove charger, wait in an indoor environment +5°C to +30°C for four to five (4-5h) hours, even longer if you suspect that temperature is too high or too low. Try again to put the EasyPower battery on charge in an indoor environment +5°C to +30°C. If the EasyPower battery still will not charge, contact service personnel.

If the EasyPower battery charges slowly it can be caused by:

o Unbalanced cells o Too high or low battery/cell temperature

Charge the EasyPower battery in an indoor environment +5°C to +30°C during at least five (5h) hours. If the charger still not indicates that the EasyPower is fully charged, contact service personnel.

Recycling The batteries shall be sent back to the importer in the country of usage or be recycled in accordance with national environmental protection regulations or disposal laws. Cell designation according to IEC 62620: ICNMP/28/149/95/H/-30+55/95 Observe that during transport the Easy Power battery shall be handled as dangerous goods, according to UN3480 Class 9.

o The external terminals shall be protected from short circuit o Normal or superannuated batteries shall be packed according to P903

Only personnel with training for transport of dangerous goods (1.3 training according to UN 38.3) are allowed to pack and mark the goods.

Repair If it is necessary to repair the EasyPower battery, some parts can be replaced by the field service but any fault in the internal parts must be repaired at a service center. Always contact your service organization*, when the EasyPower battery is suspected to be faulty and before returning the EasyPower battery. *(same as for the lift truck.) Observe that during transport the Easy Power battery shall be handled as dangerous goods, according to UN3480 Class 9.

o The external terminals shall be protected from short circuit o Damaged/defective batteries shall be packed according to P908 and LP904

Only personnel with training for transport of dangerous goods (1.3 training according to UN 38.3) are allowed to pack and mark the goods.

2016-06-09, 1004069-001 12

Appendix Declaration of Conformity Declaration of Conformity

Manufacturer Alelion Batteries AB, Flöjelbergsgatan 14C, SE 44934 Mölndal, Sweden We declare that the product listed below is in accordance with the following Directives: 2004/108/EC EMC Directive

Type of equipment: Lithium-ion battery

Product type: 1003200 EP48310CWT-CB3-E 1003500 EP48460CWT-CB3-E 1003220 EP48460CWT-CB4-E 1002943 EP48460CWT-R3-E 1003058 EP48310CWT-R2-E 1004083 EP48460CWT-R2-E 1003519 EP24310CWT-O3-E 1003904 EP24260CWT-S3-E 1003860 EP24260CWT-S6-E

EMC standard SS-EN 61000-6-2:2005 Issue 3 SS-EN 61000-6-3:2007 Issue 2 with SS-EN 61000-6-3/A1: 2011 Issue 1 Date: 2016-02-22 Fredrik Sööder, Director R&D

13 2016-06-09, 1004069-001

Material Safety Data Sheet

Instructions for the Safe Handling of EasyPower Lithium Ion Batteries Batteries are considered as articles under REACH regulation 1907/2006/EC and, as such, do not require

the publication of a safety data sheet. However, there is a requirement to provide safety information on

products. This document, which fulfils this requirement, is commonly called an MSDS, but, in Europe, is

more correctly referred to as ‘Instructions for the Safe Handling of Lead-Acid Batteries’.

Product and company identification Product: Traction Lithium Ion Battery Brand name: EasyPower Manufacturer: Alelion Batteries AB Adress: Flöjelbergsgatan 14 C, S-431 37 Mölndal, Sweden Emergency phone: + 46 31 86 62 00

Composition/information on ingredients As a solid, manufactured article, exposure to hazardous ingredients is not expected with normal use.

Hazards identification The battery is not classified as dangerous according to directive 1999/45/EEC.

There is no hazard when the measures for handling and storage are followed.

In case of cell damage, possible release of dangerous substances and a flammable gas mixture can occur.

First Aid Measures The following first aid measures are required only in case of exposure to interior battery components

after damage of the external battery casing. Undamaged, closed cells do not represent a danger to the

health.

After inhalation: Ensure of fresh air. Consult a physician.

After contact with skin: Wash off immediately with plenty of water. Consult a physician.

After contact with eyes: Rinse immediately with plenty of water, also under the eyelids, for at least

15 minutes. Seek medical treatment by eye specialist.

After ingestion: Drink plenty of water. Call a physician immediately.

Firefighting measures Suitable extinguishing media: Cold water and dry powder in large amount are applicable. Special hazards arising from the chemical: May form hydrofluoric acid if electrolyte comes into contact with water. In case of fire, the formation of the following flue gases cannot be excluded: Hydrogen fluoride (HF), Carbon monoxide and carbon dioxide. Protective equipment and precautions: Wear self-contained breathing apparatus and protective suit. Additional information: If possible, remove battery from firefighting area. If heated above 125 °C, cell(s)inside the battery can vent. Battery is not flammable but internal organic material will burn if the cell is incinerated.

2016-06-09, 1004069-001 14

Accidental Release Measures This information is relevant only if the battery is broken and the contents are released.

Personal precautions Use personal protective clothing. Avoid contact with skin, eyes and clothing. Avoid

breathing fume and gas.

Environmental precautions Do not discharge into the drains/surface waters/groundwater. Take up

mechanically and send for disposal.

Handling and storage Handling

Avoid short circuit, the battery contains a short circuit fuse.

Avoid mechanical damage.

Don’t open the battery.

Keep fire extinguisher in relevant distance

Keep away from open flames, hot surfaces and sources of ignition.

Storage

Store in-house between -30 ⁰C and + 45 ⁰C, optimum temperature is just below 20 ⁰C fore best life time.

Avoid short circuit.

Place on a pallet for easy removal in case of danger.

Exposure Controls/Personal Protection Exposure limiting values During normal charging and discharging no release of any hazardous substances occur.

Physical and Chemical properties Appearance: Form: Solid

Color: Not applicable Odor: Odorless

Important health, safety and environmental information:

pH value: Not applicable Flash point: Not applicable Lower explosion limit: Not applicable Vapor pressure: Not applicable Density: Not applicable Water solubility: Insoluble Ignition temperature: Not applicable

Stability and reactivity Stability: Stable Conditions to avoid: Keep away from open flames, hot surfaces and sources of ignition. Material to avoid: None Hazardous decomposition products: In case of fire and open cells, there is a possibility of HF and CO release. Possibility of Hazardous Reactions: Will not occur Additional information: No decomposition if stored and applied as directed.

Toxicological information If appropriately handled and if in accordance with the general hygienic rules, no damages to health have

become known.

15 2016-06-09, 1004069-001

Ecological information Ecological injuries are not known or expected under normal use. Do not flush into surface water or

sanitary sewer system.

Disposal considerations Spent lithium Ion batteries (EWC 16 06 01) are subject to regulation of the EU Battery Directive

(2006/66/EC) and its adoption into national legislation on the composition and end-of-life management of

batteries. Spent batteries are recycled in special approved facilities. The main part of the recycling is

material recycling, but also some energy recycling.

Spent batteries are taken back by the producer or importer.

Transport Information

Land transport (ADR/RID)

UN number: UN3480 ADR/RID class: 9 Classification code: M4 Marking: 9 Tunnel restriction code: E Description of the goods: LITHIUM ION BATTERIES

Marine transport (IMDG)

UN number: UN3480 IMDG code: 9 Marine pollutant: No Marking: 9 Description of the goods: LITHIUM ION BATTERIES

Regulatory information In accordance with the EU Battery Directive and the respective national legislation, lithium ion batteries

have to be marked by a crossed out dust bin. The batteries are marked with some or all of the following

hazard symbols [See back page].

Other information Release date: 18 February 2014 Revision date: 09 April 2014 Revision: B Prepared by: Alelion Batteries AB Flöjelbergsgatan 14C 431 37 Mölndal, Sverige

The information given above is provided in good faith based on existing knowledge and does not constitute an assurance of safety under all conditions. It is the user’s responsibility to observe all laws and regulations applicable for storage, use, maintenance or disposal of the product. If there are any queries, the supplier should be consulted.

However, this shall not constitute a guarantee for any specific product features and shall not establish a

legally valid contractual relationship.

2016-06-09, 1004069-001 16

Battery Markings

Warning sign

Battery danger; contains battery cells. Avoid short circuit.

Prohibition sign

Do not expose the battery of high temperature.

The EasyPower battery is built for usage up to +45˚C ambient

temperature. By safety reasons the EasyPower battery shall

not be exposed of temperatures above +85˚C.

Information sign

Read the user manual before the EasyPower battery is installed and used.

Crossed out wheelie bin

Do not dispose as waste, product must be recycled.