Elitra™ iON Lithium-ion Batteries

Introduction

The information in this document is critical for the safe handling and proper use of the Elitra™ iON lithium-ion battery for powering electrical industrial trucks. It provides global system specifications, safety measures, codes of behavior, commissioning guidelines, and recommended maintenance. This document must be retained and available for all users responsible for the battery. Users must ensure all system applications are appropriate and safe based on anticipated or encountered operating conditions.

This owner's manual contains important safety instructions. Read and understand all instructions before installing, handling, or operating the battery. Failure to follow these instructions may result in serious injury, death, destruction of property, damage to the battery, and/or void the warranty.

This manual is not a substitute for training required by local laws, entities, or industry standards for handling and operating industrial trucks or Elitra™ iON batteries. Proper instruction and training for all users must be ensured before handling the battery system.

Refer to the Terms and Abbreviations at the end of this document.

⚠️ WARNING: You may be seriously injured if you do not follow these and other related instructions.

Product Application

Elitra™ iON batteries are designed for industrial truck traction applications. Any other use is not permitted. Only EnerSys-approved chargers are to be used to charge Elitra™ iON batteries.

The truck harness used between Elitra™ iON batteries and the industrial truck is dictated by the truck OEM. The truck harness must comply with relevant standards for current carrying capability and truck interface requirements. Truck harness compliance must be confirmed by the truck OEM and/or integrator.

⚠️ WARNING: Installing the battery in a non-compliant truck is a fire risk due to the potential for improperly sized cable harnesses and will void the warranty.

Battery Architecture

Figure 1: Outer Tray Features

The battery pack features an outer tray with lifting points on both sides. A service lid provides access. A type label and a safety label are affixed to the outer tray. The outer tray lid covers the main battery structure. Cabling for charger power connection and cabling for truck power connection are visible.

Figure 2: Details of the Electrical Interface

The electrical interface includes Discharge Terminals and Charge Terminals. There is an Optional Low SoC Warning Interface Terminal. The Operator Interface Terminal (with a threaded cover if no cable is attached) and a Low-Voltage Debug Terminal (also with a threaded cover if no cable is attached) are present. Additionally, a Low-Voltage Charge Interface Terminal (with a threaded cover if no cable is attached) and an ANT for 4G connection are visible.

The battery has a modular design, allowing products to be scaled by adding power modules for increased power and energy capability. Each power module contains lithium-ion cells configured in series/parallel arrangements based on application voltage requirements. These modules include embedded cell voltage and temperature measurements for cell balancing during operation.

The battery is protected by a functional, safety-qualified Battery Management System (BMS) housed in a control module. This module contains safety components and logic to control main contactors, preventing operation under unsafe or abusive conditions. The battery, excluding the cable harness, is designed to be rated to IP54.

Safety Features:

• A functional safety-qualified electronic monitoring and control system ensures safe electrical operation (voltage, current, and temperature limits).
• A safe shutoff strategy responds if limits are violated (voltage, current, and temperature).
• A contactor and fusing strategy minimizes the impact of accidents or misuse, such as short circuits or pulling the charge plug under load.
• Ungrounded separated charging circuit.
• Dedicated handling/lifting points.
• Dedicated venting solution to mitigate impacts of outgassing.
• A steel power module and outer tray design provides mechanical protection for the battery.

Low-Voltage Debug Interface Terminal: Used for EnerSys service purposes.

Low-Voltage Interface Terminals: Multiple low-voltage interfaces on the control module require connection during commissioning, depending on end-user requirements.

Low-Voltage Charge Interface Terminal: A required connection for all batteries, linking the charge adapter to the control module for CAN communication between the battery and charger.

NOTE: For any unused connector, fasten the threaded cover to prevent ingress of foreign material.

Operator Interfaces

An operator interface is required in the truck cabin for ease of use and to alert the operator to visual or audible alerts, such as low State of Charge (SoC). This requirement can be waived if full industrial truck OEM integration options are utilized, leveraging the truck's existing operator interfaces. Such integrations require prequalification and approval from both EnerSys and the truck manufacturer.

All operator interfaces feature a push button to activate and deactivate the battery. As SoC decreases during operation, interfaces will emit a beeping alarm and provide visual warnings at the warning level SoC. Below the alert level, the alarm speed increases. Continued operation without charging will result in battery deactivation due to low SoC.

Display Interface: A multi-language display (Chinese, English, Portuguese, Spanish, French) shows real-time battery status (voltage, SoC, current, estimated remaining time), system information, unit information, fault information, user information, history, and parameter settings.

CAN Bus Connectivity: The Elitra™ iON battery can integrate into an OEM industrial truck CAN bus system for full integration. Contact your local EnerSys Representative for this option. This requires engineering consultation between EnerSys and the industrial truck OEM.

[Diagram showing Home Screen with Voltage, Buzzer, Current, SoC, Charging/Discharging status, and navigation options like Sys Info., Cell Info., Alarm Info., User Info., etc.]

[Diagrams showing System Information, Cell Information, Fault Message, User Information, Setting, and Memo screens.]

Buzzer: SoC ≤ 20%, ON 1s/OFF 2s; SoC ≤ 0%, ON 100ms/OFF 100ms.

Buzzer Turn Off Conditions: 1. Connect charger. 2. Click the symbol to turn off.

Safety

Important Safety Instructions

• Read all safety and operation instructions before operating this battery.
• Personnel involved in unpacking, handling, operating, or maintenance must receive appropriate training and use properly rated tools and personal protective equipment (PPE).
• Follow all regulatory requirements for handling electrical systems. Refer to Appendix A: Ratings Table for maximum voltage.
• Do not over-discharge or overcharge lithium-ion batteries, as this poses a substantial risk of damage.
• Store and operate the battery only within the specified operational data, limits, and environmental limits.
• Keep the battery away from heat and ignition sources.
• Do not operate the battery in hazardous environments.
• Store only in monitored areas with suitable fire control and protection per local requirements.
• Do not customize battery hardware or software as supplied by EnerSys.
• Only operate with EnerSys-approved interface devices.
• Service must only be performed by EnerSys-approved technicians.
• Dismantling the battery is not authorized except by qualified EnerSys personnel due to numerous hazards.
• If an error cannot be reset, do not attempt to continue operation until support is provided by EnerSys.
• Do not leave the truck idle in temperatures below the battery operating temperature, as the truck may become non-operational.
• Do not operate the battery in temperatures above the operating range.
• Do not expose the battery to extended periods of direct sunlight that raise its temperature above operating or storage temperatures.
• Handle and store the battery only in a dry environment.
• Do not operate the battery outdoors without suitable weatherproof protection.
• Do not immerse the battery in water.
• Do not install the battery on the underbody of an electrical industrial truck.
• Do not operate, service, or store the battery in condensing environments.
• Do not clean the battery with pressurized water.

Interoperation with Truck and Battery Charger

• Manual instructions do not replace or supersede truck and battery charger instructions.
• Operation limits in this manual do not replace or supersede permissible operation parameters of the industrial truck or battery charger.
• Battery installation impacts both electrical and mechanical safety of the truck. Consult the industrial truck OEM to ensure compatibility and compliance with OEM requirements.
• Only charge this battery with EnerSys-approved chargers for Elitra™ iON batteries.
• The battery must be installed in a truck with appropriately sized cables.

Risks Posed During Normal Operation

• Battery systems are inherently hazardous.
• Do not short battery terminals. A shorting event can cause a high current, electric arc fault emitting intense light and heat, ejecting molten metal, and releasing toxic fumes. Components may become extremely hot.
• The battery's weight and size make it cumbersome to handle.
• Always properly restrain the battery to prevent shifting, dropping, crushing, pinching, or impacting personnel or equipment.

Damaged Batteries

• Operating outside specified limits poses a substantial risk of damage; damage may not be apparent.
• If the battery experiences conditions outside allowable limits, cease operation and contact your EnerSys Service Representative.
• If the battery's mechanical integrity is compromised (e.g., case penetration, rupture), cease operation and contact your EnerSys Service Representative.
• Stop operation if power cables or connectors are crushed, pinched, or cut.
• Damaged lithium-ion batteries may spontaneously catch fire, releasing hot, flammable, corrosive, and toxic liquids/gases, including hydrofluoric acid and carbon monoxide.
• In case of battery fire, evacuate personnel and follow Fire Event Guidance.
• If liquid electrolyte contacts skin or eyes, rinse with clean water for at least 15 minutes and seek immediate medical attention.
• If liquid electrolyte is swallowed, rinse mouth and surrounding area and seek immediate medical attention.
• If gases or vapors are inhaled, move victim to fresh air and seek immediate medical attention.
• Contact with heated gases or components may cause thermal burns; treat burns and seek immediate medical attention.

Additional information is available in the Safety Data Sheet for the Lithium-ion Battery (Module) SDS.

Guidance & Limits

Fire Event Guidance

In the event of a thermal runaway (visible gas release, smoke buildup), evacuate immediately and contact Emergency Response. Do not attempt to address the fire personally. Seek immediate medical attention for respiratory irritation.

Firefighting operations must follow guidance in the Lithium-ion Battery (Module) SDS, performed by trained firefighters with full PPE and self-contained breathing apparatus. Inform emergency responders of the lithium-ion chemistry. Any indication of thermal runaway requires fire suppression. Absence of flame does not mean the event has stopped.

Large amounts of spray water can effectively cool the battery and contain a thermal runaway. After outgassing or fire suppression, store the battery safely outside for a minimum of 24 hours, monitoring temperature for potential new heat generation. If thermal runaway reoccurs, follow the same firefighting methods.

Operational Data and Limits

• Nominal capacity (C1): See Appendix A: Ratings Table.
• Nominal voltage: See Appendix A: Ratings Table.
• Discharge current (continuous): 1xC1, up to a max of 320 A (limited by traction cable harness).
• Max charge current (continuous): up to 1xC1, max 300A (limited by charger max. output current).
• Permissible truck operation battery temperature range: 14°F (-10°C) to 122°F (+50°C).
• Permissible charge operation battery temperature range: 32°F (0°C) to 122°F (+50°C).
• The BMS safely manages current limits based on temperature.

Environmental Operation Limits

• Permissible battery storage temperature range: -4°F (-20°C) to 131°F (+55°C).
• Permissible truck operation battery temperature range: 14°F (-10°C) to 122°F (+50°C).
• Permissible charge operation battery temperature range: 32°F (0°C) to 122°F (+50°C).
• Permissible relative humidity range: 0-95% non-condensing.
• EnerSys Engineering must verify and approve in writing operation in cold storage applications.

Handling & Installation

Handling

General Handling Considerations

• Unpacking and handling are permitted only for trained personnel familiar with lithium-ion battery risks and hazardous voltages (over 60V DC) for industrial trucks and lifting heavy loads.
• Avoid sudden accelerations, decelerations, drops, and other mechanical abuse conditions.
• Handling must only occur after the battery is disconnected from all electrical loads and charge sources and verified in an OFF state (operator interface screen and lights OFF). Check voltage across the traction connector to ensure contactors are open.
• Prior to lifting, secure all connectors and cables to prevent crushing, pinching, or damage. User interfaces may be removed.
• Appropriate PPE must be worn during all lifts.
• Check appropriate lifting methods and tools for safety and load control. Tools must be properly rated for weight.
• Attach lifting tools to the outer tray lifting points.
• Lift the battery vertically only; do not allow it to swing.
• Respect operational and safety instructions of the lifting gear manual.
• If handling the battery while installed on a truck (installation/removal), secure the truck to prevent movement.

NOTES:

• For transportation and storage safety, Elitra™ iON batteries are shipped at a partial SoC. Before first operation or further storage, check SoC (refer to page 5) and recharge if needed (refer to page 12).

Installation into Industrial Truck

Mechanical Installation

• The battery is designed as a drop-in replacement for lead-acid batteries in electric industrial trucks. Modifications to truck firmware, settings, or hardware may be necessary. Consult the industrial truck OEM for required modifications. Connectors, ballast, and tray size may need customization for drop-in compatibility.
• Upon receipt, check the battery and all cables, plugs, and accessories for obvious signs of damage.
• Before installation, ensure the battery is supplied with the appropriate cable harness for connection to the industrial truck.
• Follow the truck manufacturer's requirements for battery weight and center of gravity. Weight and dimensions are listed on the battery pack's type label.
• Handle the battery to mitigate the risk of drop events and crashes. Use correct tools, lifting points, and methods.

Installation & Operation

Installation into Industrial Truck (cont.)

• After placement into the truck's battery compartment, ensure the battery is mechanically fixed against movement as specified by the truck manufacturer. Re-check all cabling to ensure no cables, wires, or plugs are crushed, pinched, or cut.
• Use only EnerSys-approved fasteners, connectors, cabling, and plugs.
• Cable dimensioning and DC connecting plug vary by truck and end-user requirements. The truck harness must comply with relevant requirements for current carrying capability, voltage, and truck interface. Compliance must be confirmed by the truck OEM.

Electrical Installation

• Model numbers begin with 24V to 80V for batteries intended to replace 24V to 80V nominal lead-acid batteries.
• Connect the battery with appropriate cables and connectors to the industrial truck per the truck manufacturer's recommendation.

NOTE: Defective cables and connectors can cause functional issues or severe safety hazards (short circuits, fire). Regularly inspect cables and connectors for damage. Repairs or replacements must be done by an authorized EnerSys representative using correct factory replacement parts. No substitution is allowed.

Operation

Users must be trained on battery aspects relevant to their responsibilities, as required by local laws and regulations.

Handle, operate, store, maintain, and service the battery according to this manual's instructions. Failure to do so can result in serious damage to the battery and serious injury. Using non-original parts will void the battery warranty.

Opportunity charging is recommended to maximize daily run time and optimize service life by decreasing the discharge window.

Battery power capability decreases at low State of Charge (SoC). Operating at low SoC may result in battery shutdown with or without a 10-second warning. If this occurs, slowly drive the truck to a charger after reactivating the battery.

At very low SoC, the battery may lock out to prevent permanent cell damage.

Unlike lead-acid batteries, operating this battery at a partial state of charge is beneficial.

Battery temperature influences capacity; run time may be reduced at lower temperatures.

Battery temperatures at the extreme ends of the specified limits will influence performance, possibly resulting in unexpected shutdown.

Respect all visual and audible warnings from user interface devices.

This battery is designed to be charged indoors in the truck.

Battery

Activation/Deactivation of Battery

The battery will automatically deactivate after a default of 120 minutes of no-load condition to prevent deep discharge of an unused battery.

Activation:

Activate the battery for truck operation using the push button on any user interface. If the pack is not connected to a charger and has no errors, the battery will automatically switch to the traction state, powering the truck. The battery is also activated when plugged into the charger, allowing activation and charging even without prior activation.

Deactivation:

The battery will deactivate after a default of 120 minutes with less than a 3 A current draw. To manually deactivate, press the push button on any user interface for 3 to 5 seconds. Shut down the industrial truck before deactivating the battery.

⚠️ WARNING: If the battery is locked out due to over-discharge or missed charges during storage, pressing the push button will re-power it with limited discharge current for safety. This will further discharge the battery and may cause irreversible damage. Always recharge as soon as possible after reaching low SoC.

Battery Charging

Plug in the battery to begin charging when the battery buzzer indicates low State of Charge (SoC).

For industrial trucks, never charge via the traction connector. Connect the charging plug to the EnerSys-approved charger. While installed in the truck, the traction connector should remain connected. Plugging in the charge plug disables truck power for driveaway protection.

This battery must only be charged by EnerSys-approved lithium-ion chargers designed for CAN communication with the battery for safe and optimal operation. Follow all charger owner's manual instructions. Charging uses an ungrounded separated charging circuit.

NOTES:

• Never attempt to charge using the connector from the battery to the truck.
• Elitra™ iON Li-ion batteries are shipped at or below 30% SoC to comply with EnerSys policy for transport.

The battery system has driveaway protection that disconnects traction power if a battery charging plug is connected to a charger, preventing accidental driving away.

Charge the battery only in an appropriate environment, following all environmental requirements from the charger.

NOTES:

• The CAN-enabled charge connector must be plugged into the matching CAN-enabled charge connector on the charger. Charging will not start without CAN communication.
• While installed in the industrial truck, the battery should not be disconnected for charging, nor is it necessary to open battery compartment lids and covers.

Battery & Service

Battery Charging (cont.)

Charging Sequence

• Ensure battery and charger cables have no damage before connecting.
• Ensure connectors are free of contamination before connecting.
• Connect the charger to the battery charging cable.
• Once connected, the traction contactor opens, removing truck power for driveaway protection.
• If the battery is OFF, the charger will automatically wake it and begin charging.
• Charging begins after CAN communication starts between the battery and charger (when the CAN charging cable is connected). Optimal charge current is determined by battery conditions (SoC, temperature) and charger conditions. The charge level dynamically changes for fast charging and optimal product lifetime. Charging stops if the battery detects a fault condition.
• To stop charging before completion (e.g., opportunity charging), press the ON/OFF button on the charger before disconnecting. The battery must not be disconnected while charging.
• After a full charge cycle, the charger screen indicates completion. Current supply to the battery stops, and the charge plug should be disconnected. After disconnection, the battery automatically opens the charge path and closes the traction path, supplying power to the truck.

Service and Maintenance

The battery is designed to be virtually maintenance-free. However, external cabling, connectors, and operator interfaces must be regularly examined for damage and to comply with local regulations. Damaged or worn parts need replacement. Contact your EnerSys Service Representative for all repairs and replacements. All repairs must be performed by an EnerSys technician trained on lithium-ion products.

All power cables must be checked every time the battery has been exposed to any stress (overvoltage, overcurrent, or mechanical stresses like crushing).

Cleaning Instructions

• Clean the exterior with warm water and an antistatic cloth.
• Ensure the battery is deactivated before cleaning.
• Do not clean the battery with pressurized water.

Troubleshooting

Battery does not provide power to the truck.

• Ensure the battery is turned ON using an operator interface.
• Deactivate and reactivate the battery.
• Ensure the battery is not connected to the charger. Power to the truck is OFF during charging to prevent driving away.
• Confirm no active errors are listed on the user interface. Review the error ID checklist if errors are present.
• Inspect power cables to the truck for damage.
• If the battery has OEM integration, check communication cables between the truck and the battery.
• Contact your EnerSys Service Representative for further troubleshooting.

Battery will not charge.

• Ensure the charger is powered and displays no errors. Follow charger manual instructions if errors occur.
• Deactivate and reactivate the battery.
• Ensure charging cables are properly connected to an EnerSys lithium-ion enabled charger.
• Ensure the charge communication cable is connected to the charge communication port.
• Confirm no active errors are displayed on the battery user interface. Review the error ID checklist if errors are present.
• Check connectors, auxiliary pins, and CAN cables for damage.
• Contact your EnerSys Service Representative for further troubleshooting.

Error ID checklist and recommended actions

Premium display

Basic BDI

In case any other error ID shows up, please contact your EnerSys® Service Representative for further troubleshooting direction.

Storage & Labels

Storage

During storage, it is recommended to turn the pack ON at least every six months to confirm SoC has not dropped below 30%. Recharge to greater than 30% SoC if it has dropped below.

Store the battery in a dry environment away from fire, sparks, and heat.

Allowable storage temperatures are -4°F (-20°C) to 131°F (55°C). For battery health and maximum service life, the maximum temperature of the long-term storage location should be less than 95°F (35°C).

The storage area must comply with local regulations (including fire, safety, and building regulations) for lithium-ion batteries.

The battery must only be stored in an upright position (installed in the vehicle) with all service lids properly attached.

During storage, it is not necessary to disconnect the power connection between the industrial truck and battery. However, it is highly recommended to disconnect the truck and battery communication connector, as trickle discharge may occur.

If the battery is removed from the industrial truck for storage and one or more harnesses are removed, the battery terminals must be covered with insulation removable only by a tool, or the battery must be stored in a properly labeled, suitable container opened only by a tool or key.

For storage longer than one month, take precautions to ensure the battery is not deeply discharged. The pack must be stored at greater than 30% SoC. Processes and recharge methodology must be in place to ensure the battery does not discharge to 5% SoC in storage.

Description of Battery Labels

The label type, located on the side of the inner pack, displays important information about the battery, including Manufacturer Name & Logo, Part & Serial Number, Nominal Voltage, Nominal Capacity, and Nominal Mass.

[Image description: Example ID Plates in Chinese/English, Chinese/Spanish, and Chinese/Portuguese showing model number, voltage, capacity, etc.]

Description of Battery Labels (cont.)

[Image description: Symbols indicating the battery must be recycled, contains lithium-ion, refer to manual, warning statements, risk of electrical shock, risk of fire, risk of explosion, do not expose to naked flames, do not place in high-temperature environment, do not step on the battery.]

[Image description: Large warning labels in Chinese/English and Portuguese/Spanish, and small warning labels in Portuguese/Spanish and Chinese/English.]

Warning Label: The warning label, located on the side of the battery, contains warnings critical for the safe usage of the battery.

Shipping & Disposal

Shipping Lithium-ion Batteries

All persons involved in shipping batteries must comply with all applicable regulations.

All persons involved in shipping batteries must be trained as required by local regulations to ship hazardous goods.

Unpacking and packing of batteries shall only be performed by electrically trained personnel.

Due to their inherent stored energy and flammability, lithium-ion batteries are considered "Dangerous Goods" and must be transported in accordance with all regulations. The classification for the battery is Class 9, according to UN "Recommendations on the Transport of Dangerous Goods, Manual of Tests and Criteria", Chapter 38.3 (known as UN 38.3). Air shipment requires competent authority approval according to the local jurisdiction's department of transportation.

This battery complies with UN 38.3. Test summaries are available upon request.

Damaged batteries must be transported based on all applicable regulations for damaged lithium-ion batteries. These requirements are in addition to the standard UN 38.3 criteria. Contact your EnerSys Service Representative for assessment and support in transporting damaged batteries.

For further transport and regulatory information (USA and EU; classifications and labeling), refer to Lithium-ion Battery (Module) SDS instructions or regulations by the International Civil Aviation Organization (ICAO), International Air Transport Association (IATA), International Maritime Dangerous Goods (IMDG), Convention concerning the Carriage of Goods by Rail (CIM), and Annex A: International Regulations concerning the Carriage of Dangerous Goods by Rail (RID) codes. Other laws and regulatory requirements may apply.

Disposal and Recycling

Dispose of the battery in accordance with all local regulations relating to disposal of lithium batteries. Failure to do so may result in serious harm.

Do not dismantle, incinerate, or crush battery systems.

Dismantling the battery is not authorized except by qualified EnerSys personnel due to the numerous hazards involved with dismantling a lithium-ion battery.

In case of irreparable failure, the battery must be taken out of operation and your EnerSys® Service Representative contacted.

Due to the risks posed by damaged lithium-ion batteries, damaged lithium-ion batteries require specialized handling and recycling. Do not dispose of this battery as unsorted municipal waste.

EnerSys, in line with local regulations, will accept Elitra™ iON products at specific facilities for disposal. Contact your local EnerSys Service Representative for specific recycling instructions for your region.

Appendix A: Ratings Table

* 2 x 36V Power Modules are connected in series to 72V

** 2 x 40V Power Modules are connected in series to 80V

Terms & Abbreviations

Notes

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