EasyPower User Manual

Transcription

1 EasyPwer User Manual EP48460CWT-CB4-E ( ) EP48460CWT-CB3-E ( ) EP48310CWT-CB3-E ( )

2 Cntents General... 3 Safety... 4 Overview... 5 Operatin... 7 Trubleshting Recycling Repair Appendix Declaratin f Cnfrmity Material Safety Data Sheet Battery Markings Basic Battery Data Prduct n: EP48460CWT-CB4-E ( ) Battery Type: Li-In (NMC) Nminal Vltage: 51.8 V Nminal Capacity: 448 Ah Energy: 23 kwh Usage Temperature Range: 0 C t +45 C (ideally +15 C t +25 C) Strage Temperature: -30 C t +45 C (ideally +15 C till +25 C) Weight: 994 kg ±5% Usage: 48 V DC systems Prduct n: EP48460CWT-CB3-E ( ) Battery Type: Li-In (NMC) Nminal Vltage: 51.8 V Nminal Capacity: 448 Ah Energy: 23 kwh Usage Temperature Range: 0 C t +45 C (ideally +15 C t +25 C) Strage Temperature: -30 C t +45 C (ideally +15 C t +25 C) Weight: 856 kg ±5% Usage: 48 V DC systems Prduct n: EP48310CWT-CB3-E ( ) Battery Type: Li-In (NMC) Nminal Vltage: 51.8 V Nminal Capacity: 308 Ah Energy: 16 kwh Usage Temperature Range: 0 C t +45 C (ideally 15 C t +25 C) Strage Temperature: -30 C t +45 C (ideally 15 C t +25 C) Weight: 856 kg ±5% Usage: 48 V DC systems ,

3 EasyPwer Lithium In Battery User Manual Read this User Manual carefully befre yu use the battery. Keep the instructin fr future reference and als keep the user manual available fr the user f the battery. Installatin is nly allwed t be dne by authrized persnnel. General The EasyPwer battery cnsists f lithium-in type cells and a BMS (Battery Management System) prviding nbard intelligence fr charging, discharging and supervisin. It is intended fr installatin in electric lift trucks and material handling equipment fr indr use. This prduct presents a number f advantages ver traditinal lead-acid batteries, please read the instructins carefully and make sure t fllw them. This will ensure that yu get maximum benefit f yur EasyPwer battery. The EasyPwer battery has its wn steel enclsure that when it is munted in the uter steel tray that includes ballast, is fulfilling the lift truck manufactures recmmendatins. The EasyPwer battery is designed fr a specific lift truck mdel and cannt and shuld nt be used anywhere else. A designated charger shall be used fr charging, it is cntrlled by the EasyPwer battery via the CAN-interface. The capacity demand when yu use a lithium-in battery is as a rule lwer than a crrespnding lead-acid battery. This is due t lwer lsses during use, better lifetime prperties and the pssibility t charge faster and mre ften. Fr mre infrmatin cnsult the technical manual r cntact yur lift truck service rganizatin r the lift truck manufacturer r the imprter in yur cuntry. Fr mre infrmatin abut the advantages f the EasyPwer battery please visit: ,

4 Safety As this EasyPwer battery is f a lithium-in type and is used in an envirnment where there is a ptential risk f cnfusin with a lead-acid battery, we recmmend that all persnnel are infrmed abut the difference f the tw systems. This will prevent unsafe handling and als ensure that yu get maximum benefit frm the EasyPwer battery. The EasyPwer batteries are very safe under nrmal peratin and the nbard intelligence is designed t prevent hazardus situatin even if the EasyPwer battery is used utside nrmal parameters. Please bserve fllwing warnings befre using the battery: The Easy Pwer battery shuld nly be used in the lift truck it is intended fr, the weight and vltage are stated n the label, and shall be cnsistent with the requirements by the lift truck manufacturer. Deviatins culd damage bth the lift truck and cause injury t persnnel. D nt use the EasyPwer battery if it is damaged. D nt tuch damaged parts and cntact service persnnel. Avid creating shrt circuit between the external battery terminals and its cntacts. A shrt circuit can cause fire and injuries t persnnel. In case f fire, flames r smke frm the EasyPwer battery; While driving: stp, turn ff lift truck and leave the area. While charging: stp the charger r remve the charger cable and leave the area. Call fr assistance frm the fire department and fllw the lcal fire hazard prtcls. A small fire can be cntrlled with CO2 fire extinguisher, but a majr fire will require large amunt f water. The EasyPwer battery shall nly be cnnected t a designated charger that is cnfigured fr charging the EasyPwer battery. D nt use any ther charger, as this culd risk harming persnnel r damage the EasyPwer battery. Only use the supplied cables. If the cables are damaged, replacement cables shall be rdered frm the lift truck supplier r its representatives. Installatin r remval shuld nly be perfrmed by authrized persnnel. D nt climb r stand n tp f the EasyPwer battery. D nt pen the EasyPwer battery and access the inside. D nt place freign bjects in r n the battery tray ,

5 Overview (tpside) Lift truck negative (-) terminal 2. Lift truck cmmunicatin interface (CAN-bus cntact) 3. Charger interface (n the side wall) 4. Lift truck psitive (+) terminal 5. Battery Indicatr 6. Label with key data Cnnectin t battery terminals shall be made by M10x20-screws with a trque f 24Nm. Lifting Use the prper lift hles and lift equipment that exerts vertical lad n the fixing pints ,

6 Labels Prduct cde; identifies the battery type Electrical Prduct and technical data EC Cell designatin accrding t IEC Prduct number; specifies the exact build Serial number; unique fr each battery Custmers wn prduct number Nminal weight; with and w/ ballast Symbls; see back page fr mre inf Warning label; yellw with black text ,

7 Operatin The Easy Pwer battery has several benefits cmpared t a traditinal lead-acid battery; nticeable fr the peratr is the use f separate cnnectin fr charging. T eliminate the risk f ignring that the charger is cnnected and drive away, the nbard intelligence will nt allw the lift truck t be mved during charging. There is als a data cmmunicatin cnnectr that attaches the battery t the lift truck via a digital interface. This prvides cmmunicatin abut battery status such as SOC (State Of Charge). The charging is easy and fast, and yu can charge anytime withut cmprmising the life expectancy as with a traditinal battery. There is never any risk fr vercharging and several shrt charging pauses ver a wrk day can replace a lnger charging sessin, this is the mst effective when using a high pwered charger. Battery Indicatins The EasyPwer battery is integrated with the lift truck and its status can be read using the rdinary instrumentatin. Fr mre infrmatin abut hw and what battery specific data that is indicated (State Of Charge, fault cdes, etc.) in the lift truck instrumentatin, please refer t the lift truck user manual. There is an nbard LED-indicatr that indicates the EasyPwer battery BMS status. The green LED indicatr is lcated n tp f the EasyPwer battery. A quick blink nce each secnd indicates that the EasyPwer battery CAN cmmunicatin is active and the battery terminals can be activated if this is nt prevented by a fault cnditin. A blink ne (1) t tw (2) times every 60 secnds indicates that the EasyPwer battery is in prtect mde*, there is n CAN cmmunicatin and the battery terminals cannt be activated. *(See the subsectin Trubleshting/Prtect Mde) ,

8 Charging The Easy Pwer battery utilizes an external charger fr charging, the charging interface als has a CAN-cmmunicatin link that ensures ptimal charging cntrl. Fr mre detailed infrmatin regarding charging and the functinality such as indicatins and behavirs f the charger refer t the chargers user manual. The fllwing chargers are recmmended t be used tgether with the EasyPwer batteries cvered by this manual: Micrpwer access MA A ( ) Micrpwer access MA A ( ) Cnnect the charger cable cnnectin t the Easy Pwer battery charging cntact. Make sure the charger is ready fr charging and the charging f the EasyPwer battery will start autmatically when cmmunicatin is established. During the cnnectin the external ples are deactivated. When yu need t use the system again, stp the charger and remve and the charger cable frm the Easy Pwer battery. The EasyPwer battery is perfect fr pprtunity charging, make use f yur natural breaks and perids when lift truck is idle. The EasyPwer battery is nt damaged by charging little and ften. The charging time will depend f the utput pwer f the charger and the nminal 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 f the utput capacity f the charger, are 300A r 1C if the battery capacity is smaller than 300Ah. Example shwing estimated bulk charging time: 0 t 99% SOC: Charger utput: 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 recmmended t be dne in a temperature within +5 C t +30 C. Outside this temperature range, the charging current will be limited, and the charging will take lnger time. We recmmend that yu keep the EasyPwer battery cnnected t the charger when nt in use ,

9 Strage Please nte as all batteries the EasyPwer battery has a certain self-discharge, this is mainly due t pwer cnsumptin f the inbuilt security system. Never stre an EasyPwer battery that indicates r warns that the SOC is lw, it shuld be charged at first given pprtunity. Stre less than fur (4) weeks; n special cnsideratin needed, the battery shuld nt risk ging t prtect* due t self-discharge during this timeframe. Stre mre than fur (4) weeks; charge until full befre the lift truck / EasyPwer battery is put in t strage. Fllw this t avid ending up in prtect* mde due t the self-discharge earlier then needed. Befre it is put back in t use, charge again if needed. *(See the subsectin Trubleshting/Prtect Mde) Cntrl a stred EasyPwer battery at least every sixth (6) mnth and charge if SOC <50%. Driving Always use lift truck accrding t the manufacturer s instructins. Nrmal peratin shuld nt be any different fr the peratr until the EasyPwer battery is almst empty. This will be cmmunicated t the lift truck and it will initiate varius limitatin actins. This can be as an example; limited acceleratin and/r lwer lifting speed. When this ccurs yu are driving n the last reserve and therefre shuld stp wrking and recharge yur Easy Pwer Battery. Fr mre specific infrmatin regarding the lift truck limitatins when battery capacity reaches the end, please refer t lift truck user manual. Maintenance Maintenance is nly allwed t d be dne by instructed persnnel that have knwledge f batteries with high energy cntent. Once a week: Cntrl that the charging cnnectins are undamaged. Clean if needed, the EasyPwer battery shall nly be wiped ff when cleaning. Never use flwing water r high pressure cleaning. Once a mnth: Let the charger be cnnected t the EasyPwer battery until it indicates battery fully charged, at least nce a mnth t keep it balanced*. *(After a while with incmplete charging and lading cycles the need fr balancing might ccur. This will ensure that all cells are fully charged and that yu have all the capacity at yur dispsal. The balancing is autmatic and is dne if needed with help f the charger, at the end f the charging cycle.) Remaining maintenance shall be dne by service persnnel at ccasins that fllws rdinary service schedule fr the lift truck ,

10 Trubleshting Prtect Mde T prtect the user and the hardware cnnected as well as the EasyPwer battery; sme situatins can trigger the EasyPwer battery t g in t a prtect mde. It will then discnnect the DC utput terminals. This can be an indicatin f a prblem, but can als be triggered by usage utside the nrmal parameters, r as a last measure t avid harmful deep discharge when the battery is clse t being fully discharged. If this is due t a fault in the lift truck it will als be indicated by the lift truck instrumentatin, please refer t lift truck user manual. T bring the EasyPwer battery ut f the prtect mde, it shuld be cnnected t an active charger r as a secnd chice if n charger is available, discnnect the cable cnnectr frm the EasyPwer battery CAN -bus cnnectr and recnnect. This will if pssible reset the EasyPwer battery and bring it ut f the prtect mde, if this is nt prevented by a serius fault cnditin. Faultfinding If the EasyPwer Battery shuts dwn during use it can be caused by: Damaged cables Brken fuse T lw cell vltage T high r lw battery/cell temperature If this happens make a visual inspectin f the EasyPwer battery cnnectins, withut remving it frm lift truck. Is there any suspicin regarding damaged cables, cntact service persnnel. If n damaged cables can be detected visually, prceed with next step. Put the EasyPwer battery n charge in an indr envirnment +5 C t +30 C. Wait at least fr ne (1h) hur and try t use the EasyPwer battery again. If the EasyPwer battery des nt start r start and shut dwn again within ne r tw minutes (1-2 min), cntact service persnnel. If the EasyPwer battery cannt be charged it can be caused by: Damaged cables T high r lw battery/cell temperature The charger is faulty If this happens make a visual inspectin f the EasyPwer battery cnnectins, withut remving it frm the lift truck. Is there any suspicin regarding damaged cables, cntact service persnnel. If n damaged cables can be detected visually, prceed with next step. Try anther charger, if it still refuses t charge, prceed with next step ,

11 Remve charger, wait in an indr envirnment +5 C t +30 C fr fur t five (4-5h) hurs, even lnger if yu suspect that temperature is t high r t lw. Try again t put the EasyPwer battery n charge in an indr envirnment +5 C t +30 C. If the EasyPwer battery still will nt charge, cntact service persnnel. If the EasyPwer battery charges slwly it can be caused by: Unbalanced cells T high r lw battery/cell temperature Charge the EasyPwer battery in an indr envirnment +5 C t +30 C during at least five (5h) hurs. If the charger still nt indicates that the EasyPwer is fully charged, cntact service persnnel. Recycling The batteries shall be sent back t the imprter in the cuntry f usage r be recycled in accrdance with natinal envirnmental prtectin regulatins r dispsal laws. Cell designatin accrding t IEC 62620: ICNMP/28/149/95/H/-30+55/95 Observe that during transprt the Easy Pwer battery shall be handled as dangerus gds, accrding t UN3480 Class 9. The external terminals shall be prtected frm shrt circuit Nrmal r superannuated batteries shall be packed accrding t P903 Only persnnel with training fr transprt f dangerus gds (1.3 training accrding t UN 38.3) are allwed t pack and mark the gds. Repair If it is necessary t repair the EasyPwer battery, sme parts can be replaced by the field service but any fault in the internal parts must be repaired at a service center. Always cntact yur service rganizatin*, when the EasyPwer battery is suspected t be faulty and befre returning the EasyPwer battery. *(same as fr the lift truck.) Observe that during transprt the Easy Pwer battery shall be handled as dangerus gds, accrding t UN3480 Class 9. The external terminals shall be prtected frm shrt circuit Damaged/defective batteries shall be packed accrding t P908 and LP904 Only persnnel with training fr transprt f dangerus gds (1.3 training accrding t UN 38.3) are allwed t pack and mark the gds ,

12 Appendix Declaratin f Cnfrmity Declaratin f Cnfrmity Manufacturer Alelin Batteries AB, Flöjelbergsgatan 14C, SE Mölndal, Sweden We declare that the prduct listed belw is in accrdance with the fllwing Directives: 2004/108/EC EMC Directive Type f equipment: Lithium-in battery Prduct type: EP48310CWT-CB3-E EP48460CWT-CB3-E EP48460CWT-CB4-E EP48460CWT-R3-E EP48310CWT-R2-E EP48460CWT-R2-E EP24310CWT-O3-E EP24260CWT-S3-E EP24260CWT-S6-E EMC standard SS-EN :2005 Issue 3 SS-EN :2007 Issue 2 with SS-EN /A1: 2011 Issue 1 Date: Fredrik Sööder, Directr R&D ,

13 Material Safety Data Sheet Instructins fr the Safe Handling f EasyPwer Lithium In Batteries Batteries are cnsidered as articles under REACH regulatin 1907/2006/EC and, as such, d nt require the publicatin f a safety data sheet. Hwever, there is a requirement t prvide safety infrmatin n prducts. This dcument, which fulfils this requirement, is cmmnly called an MSDS, but, in Eurpe, is mre crrectly referred t as Instructins fr the Safe Handling f Lead-Acid Batteries. Prduct and cmpany identificatin Prduct: Tractin Lithium In Battery Brand name: EasyPwer Manufacturer: Alelin Batteries AB Adress: Flöjelbergsgatan 14 C, S Mölndal, Sweden Emergency phne: Cmpsitin/infrmatin n ingredients As a slid, manufactured article, expsure t hazardus ingredients is nt expected with nrmal use. Hazards identificatin The battery is nt classified as dangerus accrding t directive 1999/45/EEC. There is n hazard when the measures fr handling and strage are fllwed. In case f cell damage, pssible release f dangerus substances and a flammable gas mixture can ccur. First Aid Measures The fllwing first aid measures are required nly in case f expsure t interir battery cmpnents after damage f the external battery casing. Undamaged, clsed cells d nt represent a danger t the health. After inhalatin: Ensure f fresh air. Cnsult a physician. After cntact with skin: Wash ff immediately with plenty f water. Cnsult a physician. After cntact with eyes: Rinse immediately with plenty f water, als under the eyelids, fr at least 15 minutes. Seek medical treatment by eye specialist. After ingestin: Drink plenty f water. Call a physician immediately. Firefighting measures Suitable extinguishing media: Cld water and dry pwder in large amunt are applicable. Special hazards arising frm the chemical: May frm hydrfluric acid if electrlyte cmes int cntact with water. In case f fire, the frmatin f the fllwing flue gases cannt be excluded: Hydrgen fluride (HF), Carbn mnxide and carbn dixide. Prtective equipment and precautins: Wear self-cntained breathing apparatus and prtective suit. Additinal infrmatin: If pssible, remve battery frm firefighting area. If heated abve 125 C, cell(s)inside the battery can vent. Battery is nt flammable but internal rganic material will burn if the cell is incinerated ,

14 Accidental Release Measures This infrmatin is relevant nly if the battery is brken and the cntents are released. Persnal precautins Use persnal prtective clthing. Avid cntact with skin, eyes and clthing. Avid breathing fume and gas. Envirnmental precautins D nt discharge int the drains/surface waters/grundwater. Take up mechanically and send fr dispsal. Handling and strage Handling Avid shrt circuit, the battery cntains a shrt circuit fuse. Avid mechanical damage. Dn t pen the battery. Keep fire extinguisher in relevant distance Keep away frm pen flames, ht surfaces and surces f ignitin. Strage Stre in-huse between -30 ⁰C and + 45 ⁰C, ptimum temperature is just belw 20 ⁰C fre best life time. Avid shrt circuit. Place n a pallet fr easy remval in case f danger. Expsure Cntrls/Persnal Prtectin Expsure limiting values During nrmal charging and discharging n release f any hazardus substances ccur. Physical and Chemical prperties Appearance: Frm: Slid Clr: Nt applicable Odr: Odrless Imprtant health, safety and envirnmental infrmatin: ph value: Nt applicable Flash pint: Nt applicable Lwer explsin limit: Nt applicable Vapr pressure: Nt applicable Density: Nt applicable Water slubility: Insluble Ignitin temperature: Nt applicable Stability and reactivity Stability: Stable Cnditins t avid: Keep away frm pen flames, ht surfaces and surces f ignitin. Material t avid: Nne Hazardus decmpsitin prducts: In case f fire and pen cells, there is a pssibility f HF and CO release. Pssibility f Hazardus Reactins: Will nt ccur Additinal infrmatin: N decmpsitin if stred and applied as directed. Txiclgical infrmatin If apprpriately handled and if in accrdance with the general hygienic rules, n damages t health have becme knwn ,

15 Eclgical infrmatin Eclgical injuries are nt knwn r expected under nrmal use. D nt flush int surface water r sanitary sewer system. Dispsal cnsideratins Spent lithium In batteries (EWC ) are subject t regulatin f the EU Battery Directive (2006/66/EC) and its adptin int natinal legislatin n the cmpsitin and end-f-life management f batteries. Spent batteries are recycled in special apprved facilities. The main part f the recycling is material recycling, but als sme energy recycling. Spent batteries are taken back by the prducer r imprter. Transprt Infrmatin Land transprt (ADR/RID) UN number: UN3480 ADR/RID class: 9 Classificatin cde: M4 Marking: 9 Tunnel restrictin cde: E Descriptin f the gds: LITHIUM ION BATTERIES Marine transprt (IMDG) UN number: UN3480 IMDG cde: 9 Marine pllutant: N Marking: 9 Descriptin f the gds: LITHIUM ION BATTERIES Regulatry infrmatin In accrdance with the EU Battery Directive and the respective natinal legislatin, lithium in batteries have t be marked by a crssed ut dust bin. The batteries are marked with sme r all f the fllwing hazard symbls [See back page]. Other infrmatin Release date: 18 February 2014 Revisin date: 09 April 2014 Revisin: B Prepared by: Alelin Batteries AB Flöjelbergsgatan 14C Mölndal, Sverige The infrmatin given abve is prvided in gd faith based n existing knwledge and des nt cnstitute an assurance f safety under all cnditins. It is the user s respnsibility t bserve all laws and regulatins applicable fr strage, use, maintenance r dispsal f the prduct. If there are any queries, the supplier shuld be cnsulted. Hwever, this shall nt cnstitute a guarantee fr any specific prduct features and shall nt establish a legally valid cntractual relatinship ,

16 Battery Markings Warning sign Battery danger; cntains battery cells. Avid shrt circuit. Prhibitin sign D nt expse the battery f high temperature. The EasyPwer battery is built fr usage up t +45 C ambient temperature. By safety reasns the EasyPwer battery shall nt be expsed f temperatures abve +85 C. Infrmatin sign Read the user manual befre the EasyPwer battery is installed and used. Crssed ut wheelie bin D nt dispse as waste, prduct must be recycled ,