EasyPower AGV EP48460P-R1-T-A 1004940, 1004955
EP24260P-S5-T-A 1005385 English - English See back cover for other available languages or visit: www.alelion.com/sv/usermanuals
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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 with the correct ballast mounted on the sides or mounted in an 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 or via analog charging signals to charging plate for auto charging of AGV-solutions. 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.
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Basic Battery Data Common data for all batteries (listed below):
Battery Type: Li-Ion (NMC) Usage Temperature Range: 0°C to +45°C
(ideally +15°C till +25°C) Storage Temperature: -30°C to +45°C
(ideally +15°C till +25°C)
Conforms to and approved: For usage in the EU: CE mark compliance For usage in Russia: EAC mark compliance For usage in Morocco: Cp mark compliance EP24260P-S5-T-A (1004955, 1005385) EP48460P-R1-T-A (1004940)
Product specific data:
Product no: EP24260P-S5-T-A (1004955, 1005385) Nominal Voltage: 25.9 V Rated Capacity: 252 Ah Energy: 7 kWh Weight: 130 kg ±5% (battery part only) Usage: 24 V DC systems
Product no: EP48460P-R1-T-A (1004940) Nominal Voltage: 51,8 V Rated Capacity: 448 Ah Energy: 23 kWh Weight: 356 kg ±5% (battery part only) Usage: 48 V DC systems
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Safety 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. See the product MSDS for more information.
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.
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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.
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Overview 24V Systems
The EP24260P-S5-T-A battery is designed for use with Automated Guided Vehicles (AGV’s). Due to lack of space inside the battery, the solution has an external box, denoted auto box to house the AGV battery specific electronics. This allows for automated charging via an external connection plate with constant power to the AGV.
The auto box contains the following electronic functions:
o A signal interface towards the charger via the charger plate.
o Two contactors for switching the positive and negative terminals to the charger independently.
Please observe that the first series of the EP24260P-S5-T-A battery (art no: 1004955) and accompanying auto box differs slightly from the facts stated in this manual. It has only one set of terminals on the auto box so the battery must have dual power cables mounted on its terminals, one to the auto box and one to the AGV. These should be connected to the battery terminals with a M10x25mm screw with a spring washer and plain washer on top of the cable shoes and by using a torque of 24Nm. The signal connector to the auto box from the battery is in form of a short cable with a connector, it is protruding from the signal tower. The signal controlling charging when using the charger plate is an analog signal: - High/low signal, the BMS controls the amount of charge current. - Detect/Pilot signal, a bidirectional signal for the BMS to detect the presence of the charger, and for the BMS to turn on the charger current.
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(AGV box topside)
(24V stacker type topside)
1. AGV box communication interface 6P (CAN-bus) 2. Battery Indicator 3. AGV box positive (+) terminal / Lift truck positive (+) terminal 4. Manual charger interface (with the discharge bridge) 5. Label with key data 6. Lift truck communication interface 8P (CAN-bus) 7. AGV box negative (-) terminal / Lift truck negative (-) terminal 8. Charger plate negative (-) terminal 9. Charger plate signal connection 10. Charger plate positive (+) terminal
2
6
3
1
7
4
4
2 4
2 4
5
22
Charger plate
2 2
2 2 2 2
2 2 2 2
1 3
7
8
9
10
2 2 2 2
2 2 2 2
3
7
2 2 2 2
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48V Systems The EP48460P-R1-T-A battery is designed for use with Automated Guided Vehicles (AGV’s). The AGV battery specific electronics is added inside the battery. The “charger positive terminal”, “charger negative terminal” and the “charger communication interface connector” is added and allows the automated charging via an external connection plate with constant power to the AGV. (48V reach type topside)
(The illustration shows inner battery tray only)
1. Charger positive (+) terminal 2. Lift truck positive (+) terminal 3. Battery Indicator 4. Lift truck communication interface 8P (CAN-bus) 5. Manual charger interface (with the discharge bridge) 6. Label with key data 7. Charger negative (-) terminal 8. Lift truck negative (-) terminal 9. Charger communication interface 6P (CAN-bus)
Terminal Connections Connection to battery and auto box terminals is done by the supplied M10x20-screws with a plain washer and spring washer used on top of the cable shoe and using a torque of 24Nm.
rer
2 2 2
4 2 2 2
5 7 4 2 2 2
4 2 2 2
6 8 8 2 2 2
1 2 3 4
4 2 2 2
9
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Lifting Use the proper lift holes and lift equipment that exerts vertical load on the fixing points. Lift device should be attached to both of the two outer lift eyes on each side; the angle should not exceed 15 degrees from the vertical along the short side of the battery. REACH TYPE: (short side) (long side) STACKER (24V) TYPE:
< 15° < 15°
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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. As an extra safety feature, there is also an external discharge bridge, that must be connected to the charger interface before the EasyPower battery terminals becomes active.
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 fast and easy, 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 indicator that indicates the EasyPower battery BMS status; the green LED is located on top of the EasyPower battery: o A quick blink once each second indicates that the EasyPower battery CAN
communication is active and the EasyPower battery is ready for use.
o 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)
o No blink indicates a permanent fault condition and the EasyPower battery will not be usable, contact service personnel.
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Charging The Easy Power battery utilizes an external charger for charging, the manual 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. When the auto charging option is used and the auto box connects to a charger via a charger plate, the charger is controlled by the same CAN signals that is used for manual charging. 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. However, it is recommended that you charge it full at least once a month, to keep it balanced, see the subsection maintenance. 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. 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.
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 two (2) weeks for 24V, or four (4) weeks for 48V battery; No special consideration needed, the EasyPower battery should not risk go in to protect* mode due to self-discharge during this timeframe. Store more than two (2) weeks for 24V, or four (4) weeks for a 48V battery; 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 it again if needed. Control a stored EasyPower battery at least every sixth (6) month and charge if SOC <50%.
*(See the subsection Troubleshooting/Protect Mode)
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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.
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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 EasyPower 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, the preferred option is to connect the EasyPower battery to an active charger. A secondary option e.g. to use if the charger is unavailable, is to re-connect (toggle) the lift truck communication interface connector to the Easy Power battery 8 pin CAN-bus connector (no6 on page 7, no4 on page 8). Both measures will reset the EasyPower battery and bring it out of the protect mode, if this is not prevented by a serious fault condition.
Service Required Mode If an input value is critically out of it expected range it will trigger the EasyPower battery to permanently disable the output and input for safety reasons. When an EasyPower battery is in service required mode the only way to reset is via software, if you suspect your battery has ended up in service required mode contact service personnel. Only a qualified service engineer that has evaluated the problem should perform a reset.
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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. 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.
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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
Repair
If it is necessary to repair the EasyPower battery, some parts can be replaced by the field service but complex faults must be repaired at a service center. Always contact your service organization (the same as for the lift truck), when the EasyPower battery is suspected to be faulty and before returning the EasyPower battery.
Transport Observe that during most transport situations the EasyPower battery shall be handled as dangerous goods, according to UN3480 Class 9.
o The external terminals shall be protected from short circuit o Normal batteries shall be packed according to P903* o Batteries sent for recycling shall be packed according to P909* 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. *(ADR/RID or IMDG)
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