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Owner's Manual for EnerSys models including: 0323, 0125, 24-L1-24-14.2 NexSys iON Advanced Lithium-Ion Battery, NexSys iON Advanced Lithium-Ion Battery, Advanced Lithium-Ion Battery, Lithium-Ion Battery, Battery
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DocumentDocumentBattery OWNER'S MANUAL www.enersys.com UL Listing applies to certain models only. CONTENTS Introduction ...................................... 3 Product Application .......................... 4 Battery Architecture.......................... 4 Operator Interfaces........................... 7 Safety................................................. 9 Fire Event Guidance ......................... 11 Operational Data and Limits............ 11 Environmental Operation Limits..... 11 Handling ............................................ 12 Installation into Industrial Truck ...... 12 Operation .......................................... 13 Battery Activation/Deactivation ...... 14 Battery Charging............................... 14 Service and Maintenance ................ 15 Troubleshooting................................ 16 Storage .............................................. 17 Battery Label Description ................ 18 Shipping Lithium-ion Batteries ....... 19 Disposal and Recycling .................... 19 Appendix A & B................................. 20 Terms and Abbreviations ................. 23 2 INTRODUCTION The information contained in this document is critical for safe handling and proper use of the NexSys® iON lithium-ion battery for powering electrical industrial trucks or Automated Guided Vehicles (AGVs). It contains a global system specification as well as related safety measures, codes of behavior, a guideline for commissioning and recommended maintenance. This document must be retained and available for users working with and responsible for the battery. All users are responsible for ensuring that all applications of the system are appropriate and safe, based on conditions anticipated or encountered during operation. 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 owner's manual is not intended as a substitute for any training on handling and operating the industrial truck or NexSys® iON battery that may be required by local laws, entities and/or industry standards. Proper instruction and training of all users must be ensured prior to any handling of the battery system. Refer to the Terms and Abbreviations at the end of this document. For service, contact your sales representative or call: 1-800-ENERSYS (USA) 1-800-363-7797 For other regions, please visit https://www.enersys.com/en/sales-services/ www.enersys.com Your Safety and the Safety of Others is Very Important WARNING You may be seriously injured if you don't follow these and other related instructions. 3 PRODUCT APPLICATION Product Application NexSys® 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 NexSys® iON batteries. The truck harness used between NexSys® iON batteries and the industrial truck is dictated by the truck OEM. The truck harness shall comply with requirements in relevant standards for current carrying capability and truck interface requirements (UL 583 for UL certification or EN 1175 and EN 60204-1 for CE and UKCA certification). Truck harness compliance with relevant standards shall 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 The parts of the battery are shown in Figure 1. View of inner pack of the battery in Figure 2. Figure 1: Outer Tray Features Figure 2: Inner Pack Features Figure 3: Details of the Electrical Interface Outer Tray Lifting Points (same as other side) Optional Positioning for Charge Power Connection (multiple around the tray) Outer Truck Terminals Tray Safety Label Protective Covers (only if no cable is attached) Truck Interface Jumper (blue plug in the Truck Interface Terminal, not shown) Outer Tray Outer Tray Truck Interface Terminal Battery Vents (threaded cover if no cable is attached) Low-Voltage Debug Terminal (threaded cover if no Electrical Interfaces CDI cable is attached) on Cover of Operator Interface Control Module Terminal (threaded cover if no Figure 3 cable is attached) Charge Terminals Low-Voltage Charge Interface Terminal (threaded cover if no cable is attached) Inner Pack Safety Label Cabling for Truck Power Connection Outer Tray Lid Outer Tray Type Label Marking of Weight on Outer Tray (AMER Battery only) Figure 1* Cabling for Charge Power Connection Inner Pack Lifting Pack (same on other side) Steel Inner Pack Y-Harness for User Interface Inner Pack Battery Vent * Example:The overall shape, the number of plugs and plug positions can vary based on model ** Not applicable for range extension 4 Inner Pack Type Label (under plugs, same as other side) Figure 2** BATTERY ARCHITECTURE Battery Architecture (cont.) Figure 4: AGV Single Cable Application For AGV single cable applications: truck and recharge connector For AGV single cable applications: truck and recharge terminals For AGV single cable applications: do not use charge terminals Figure 5: AGV Multiple Cable Application For AGV multiple cable applications: truck and recharge connector For AGV multiple cable applications: extra recharge connector for max 640 A For AGV multiple cable applications: truck and recharge terminals--mandatory connection For AGV multiple cable applications: use to increase recharge speed up to 640A 5 BATTERY ARCHITECTURE Battery Architecture (cont.) The battery has a modular design. The power modules allow products to be scaled to an application by adding additional power modules to provide more power and energy capability for a given assembly. The power modules contain lithium-ion cells, which are assembled into various series/parallel configurations depending on the application voltage requirements. The power module contains embedded cell voltage and temperature measurements along with the capability to balance the cells during operation. The battery is protected by a functional safety-qualified Battery Management System (BMS) which is packaged into a control module. This control module contains safety components and logic to control main contactors, preventing the operation of the battery in unsafe and abusive conditions. The battery, excluding cable harness, is designed to be rated to IP54. Safety Features: · A functional safety-qualified electronic monitoring and control system to ensure safe electrical operation (voltage, current, and temperature limits) · A safe shutoff strategy to respond if limits have been violated (voltage, current, and temperature) · A contactor and fusing strategy to minimize the impact of accidents or misusing the battery like short circuits or pulling the charge plug under load · Ungrounded separated charging circuit · Dedicated handling/lifting points · Dedicated venting solution to mitigate the impacts of the resulting outgassing · A steel inner pack to provide mechanical protection for the battery · Certain models only: Emergency Stop Button close to the charge plug location to disconnect main terminal power Low-Voltage Debug Interface Terminal: Debug interface used for EnerSys® service purposes. UL HV models only: Connects the Emergency Stop Button and is used for service purposes. Low-Voltage Interface Terminals: There are multiple lowvoltage interfaces on the outside of the control module which must be connected during commissioning, depending on the end user requirements. Low-Voltage Charge Interface Terminal: This is a required connection for all batteries. This interface connects the charge adapter to the control module, allowing for the required CAN communication between the battery and the charger. AGV models only: This interface is connected to the traction cable in single cable applications, as the service concept requires a standard charger to be able to charge the battery, fulfilling inadvertent movement safety protocols. In multiple cable applications, the service personnel are responsible for preventing inadvertent movement by disconnecting the truck from the battery manually before connecting the charger. Truck Interface Terminal: This optional interface provides the possibility to provide specific integration functions if the battery is to be fully integrated into the truck. The truck interface is not a requirement from EnerSys® but may be required by the truck manufacturer. Truck Warning and Interlock Integration: The battery provides an Early Warning Signal (EWS) output and interlock input that must be looped back for the battery to operate. In truck integrations, the truck may monitor the EWS and can also command a shutdown by breaking the loop. · Interlock: Allows the truck to send a signal to tell the battery to shut down. · Early Warning Signal (EWS): Battery provides a discrete signal to the truck 10 seconds before battery shutdown. · Jumper: If installed, do not remove the cap on this connection as this may result in the battery no longer operating. This provides interlock loop functionality on drop-in batteries requiring no additional truck integration effort. · If the use of this signal as the interface with the truck is necessary and it was not previously discussed with EnerSys®, please contact your EnerSys® Service Representative for support, as prequalification and a specific cable are required. · External Key Signal: If implemented, truck key actuation allows the user to turn on the battery. 6 OPERATOR INTERFACES Battery Architecture (cont.) · Operator Interface Terminal: Connection point for Y-harness that connects to CDI (CAN Data Interface) and the optional user interfaces. The low-voltage interfaces are protected by a 0.5 A fuse. Low-Voltage Debug Interface Terminal: Debug interface used for EnerSys® service purposes. NOTE: For any unused connector, the threaded cover must be fastened in place to prevent the ingress of foreign material. Operator Interfaces An operator interface is required to be installed into the truck cabin for ease of use and to ensure the operator is alerted to any visual or audible alerts such as low State of Charge (SoC).This in-cabin operator interface can be either the Battery Discharge Indicator or theTruck iQTM smart battery dashboard. Display Screen Truck Communication Cable (CAN) This requirement of an in-truck interface can only be eliminated if full industrial truck OEM integration options are utilized, allowing the truck's existing operator interfaces to be utilized.Truck OEM integrations require prequalification and approval from both EnerSys® and the truck manufacturer. All operator interfaces are equipped with a push button that can activate and deactivate the battery. During operation as the SoC decreases, the operator interfaces will begin to emit an audible beeping alarm and provide visual warnings when the battery reaches the Warning Level SoC. After the battery drops below the Alert Level, the alarm will increase in speed. Continuing to run the battery without charging will ultimately result in the battery deactivating due to low SoC. All operator interfaces connect to the battery via the Y-harness cable for the operator interfaces. Figure 6: CAN Data Interface (CDI) The main purpose of the CDI is to control the flow of information from the BMS to external data platforms, including allowing a CAN bus connection between the battery and industrial truck if the customer decides on this option. Using CAN bus connectivity allows data and warnings to be displayed via the industrial truck dashboard instead of other operator interface devices. Please consult EnerSys® on this option, as it requires engineering consultation and prequalification with the industrial truck OEMs. ON/OFF Button Battery Cable Figure 6 All batteries will be supplied with the CDI, which is attached directly to the battery or via theY-harness. In most cases, the CDI will be hidden once the battery is installed into an industrial truck.The CDI does feature an activation/deactivation button and LED display to allow interaction with the battery if accessible or when a battery is outside of an industrial truck. The buzzer and LED behavior for the devices is as follows: · Warning SoC ON 1 sec./OFF 1 sec. · Alert SoC ON 0.5 sec./OFF 0.5 sec. · BMS error ON 0.1 sec./OFF 0.1 sec. For full truck integration, the CAN cable must be connected from the CDI to the truck. NOTE: In the case of full industrial truck OEM integration, the battery will cease to function if the CDI or wires to the CDI are broken. Contact your EnerSys® Service Representative for repair or replacement. The CDI data can be read wirelessly through the E ConnectTM app available on both iOS® and AndroidTM platforms. Contact your EnerSys® Service Representative for login details. 7 OPERATOR INTERFACES Operator Interfaces (cont.) Battery Discharge Indicator (BDI):This device can be installed outside of the battery compartment to allow operators to view the SoC and the presence of a battery error as well as to provide easy access to an activation/deactivation button.The series of lights will indicate SoC, whilst audible alarms will notify the operator that the battery requires recharging or that there are battery errors. Continued operation after the BDI indicates low SoC will ultimately result in the deactivation of the battery due to low SoC.The BDI must be permanently and securely fixed in a position for the operator to view the BDI for information and access the button. State of Charge Indicator Activation Button Figure 7 Figure 7: Battery Discharge Indicator (BDI) Figure 8: State of Charge Indicator Logic on BDI Truck iQTM Smart Battery Dashboard: Figure 9: Truck iQTM Smart Battery Dashboard SoC Truck iQTM:TheTruck iQTM smart battery dashboard is an operator interface that provides operators with more detailed battery information.TheTruck iQTM device includes the activation/deactivation button, audible alarms, and visual alarms.TheTruck iQTM device must be installed per the installation instructions provided with theTruck iQTM smart battery dashboard.TheTruck iQTM device must be permanently and securely fixed in a position for the operator to view the information and access the button. Button 100% <75% <50% Display <25% Low SoC or Error Figure 8 Buzzer Refer toTruck iQTM smart battery device manual for further information. Emergency Stop Button/Manual Service Disconnect UL HV models only: Pushing the Emergency Stop Button interrupts the power supply to the coils of the main power contactors, interrupting the connection to the main power terminals.The button is illuminated by a red LED that is always on in case of active main power terminals. If the battery is turned OFF, or the Emergency Stop Button is engaged, the LED turns off. Figure 9 CAN Bus Connectivity:The NexSys® iON battery can be integrated into an OEM industrial truck CAN bus system which allows full integration of the battery. Please contact your local EnerSys® Representative for this option. This option requires engineering consultation between EnerSys® and the industrial truck OEM. To engage the Emergency Stop Button, it must be pushed. To disengage the Emergency Stop Button, it must be turned as indicated by the arrows on the button. 8 SAFETY Safety Important Safety Instructions · Read all safety and operation instructions before operating this battery. · Anybody involved in unpacking, handling, operating, or maintenance of this battery must receive appropriate training and use appropriately rated tools and personal protective equipment. · Follow all regulatory requirements for handling electrical systems.The voltage of an electrical system may impact what regulations are applicable. To determine the maximum voltage for this battery, see Appendix A: RatingsTable. · Do not over-discharge or overcharge lithium-ion batteries as this poses a substantial risk of damaging the battery. · Only store and operate the battery within the limitations given in the sections on operational data and limits, and environmental limits. · Keep the battery away from heat sources. · Keep the battery away from ignition sources. · Do not operate the battery in hazardous environments. · Store only in monitored areas with suitable fire control and protection per local requirements, including local fire regulations. · Operate only in monitored areas with suitable fire control and protection per local requirements, including local fire regulations. · Do not customize the battery hardware or software as supplied by EnerSys®. · Only operate with EnerSys®-approved interface devices. · AGV Models: · Selection and implementation of correct ratings for cables and connectors shall be the responsibility of the Vehicle OEM and integrator/ customer ensuring that an adequate number of cables are installed to support projected application current limits to avoid thermal electric hazards. · Insulation monitoring shall be implemented by the vehicle OEM, integrator, or customer, ensuring compliance to proper regulations and standards. · Vehicle OEM and integrator/customer is responsible for charging plates management as specified in ISO 3691. · Vehicle OEM and integrator/customer is responsible for inadvertent movement safety function while product is charging. · The battery must be installed in a truck with an appropriate number of connected cables. · Service of the battery must only be performed by EnerSys®-approved technicians. · Dismantling the battery is not authorized except by qualified EnerSys® personnel due to the numerous hazards involved with dismantling a lithium-ion battery. · In the case of any error that cannot be reset, do not attempt to continue the operation of the battery until support and direction is provided by EnerSys®. · Do not leave the truck idle in temperatures below the battery operating temperature as this may result in the truck becoming non-operational. If the battery's internal temperature is below the operating range it will not provide power to operate the truck. · Do not attempt to operate this battery in temperatures above the operating range. · Do not expose the battery to extended periods of direct sunlight that allow the temperature of the battery to rise above the storage or operating temperatures of the battery. · Only handle and store the battery 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 (activated or deactivated), service or store battery in condensing environments. · Do not clean the battery with pressurized water. · HV Models: · Touchproof IP2x connectors shall be utilized for all HV interfaces to protect against electric shock hazards. · Exposed HV connections (terminals) shall be touchproof and insulated with a method requiring a tool to remove (heat shrink insulation recommended) · UL HV models only: The battery is equipped with an Emergency Stop Button. Pressing this button disconnects the main power from the terminals for service or emergency purposes. 9 SAFETY Safety (cont.) Interoperation with Truck and Battery Charger · The instructions in this owner's manual do not replace or supersede the instructions for the truck and battery charger. · The operation limits given in this owner's manual do not replace or supersede the permissible operation parameters of the industrial truck or battery charger. · Installation of this battery impacts both the electrical and mechanical safety of the truck. Consult with the industrial truck OEM to ensure this battery is compatible with the truck and complies with the OEM requirements. · Only charge this battery with EnerSys®-approved chargers for NexSys® iON batteries. · The battery must be installed in a truck with appropriately sized cables. Risks Posed During Normal Operation · This battery is designed to be stable and tolerant to the applications within the scope laid out in the operating conditions; however, battery systems are inherently hazardous. · Do not short the battery terminals. A shorting event with a high current may occur because of the low internal resistance of the lithium-ion battery. A resulting electric arc fault may emit an intense hot flash of infrared, visible, and ultraviolet light. Molten and vaporized metal may be ejected. Toxic fumes may be released. Components may become extremely hot. · The weight and size of the battery make it cumbersome to handle. · Always properly restrain the battery. Failure to restrain the battery may result in the battery shifting or dropping. Additionally, this may result in the battery crushing, pinching, or impacting personnel or nearby equipment. Damaged Batteries · Exposure of the battery to conditions outside of its operational and environmental limits poses a substantial risk of damage to the battery. Do not assume that damage to the battery will be apparent. · If the battery experiences conditions outside of the allowable limits as stated in this document, cease and do not resume operation, and contact your EnerSys® Service Representative. · If the mechanical integrity of the battery is compromised (e.g., penetration of the case, rupture of case, etc.) cease and do not resume operation of the battery and contact your EnerSys® Service Representative. · Stop the operation of the battery if there is a crush, pinch, cut or other damage to the power cables or power connectors. · Damaged lithium-ion batteries may spontaneously catch fire. If this occurs the battery may release jets of hot, flammable, corrosive, and toxic liquids/gases, smoke containing components such as hydrofluoric acid and carbon monoxide. · In case of battery fire, evacuate all personnel from the area and follow the guidance in the Fire Extinguishing section of this manual. 10 · If any material from a damaged battery, such as liquid electrolyte, comes into contact with a person's skin or eyes, rinse the affected areas with clean water for at least 15 minutes.Then immediately obtain medical attention. · If any material from a damaged battery, such as liquid electrolyte, comes into contact with the mouth or is swallowed, rinse out the mouth and the area around the mouth.Then immediately obtain medical attention. · If gases or vapors produced by a damaged battery are inhaled, move the victim to fresh air. Immediately obtain medical attention. · Contact with heated gases or components of a damaged battery may cause serious thermal burns. Treat any thermal burns, then immediately obtain medical attention. · UL HV models only: The battery is equipped with an Emergency Stop Button. Push this button to disconnect main power from the terminals.This will interrupt the connection to an external source of failure (e.g. damaged truck cables) but will not stop internal thermal processes if already started. Additional information can be found in the Safety Data Sheet for the Lithium-ion Battery (Module) SDS:829515. FIRE GUIDANCE & LIMITS Fire Event Guidance In the unlikely event of a thermal runaway, which may result in a visible release of gas and/or intensive smoke buildup from the battery, evacuate the location immediately and contact Emergency Response. Do not attempt to personally address the fire event or approach the product. If there is an irritation of the respiratory tract, seek immediate medical attention. Firefighting operations must be performed based on guidance provided in the Lithium-ion Battery (Module) SDS:829515 by trained firefighters with full personal protective equipment and self-contained breathing apparatus. Ensure that emergency responders are informed that the battery has lithium-ion chemistry. Any indication of a thermal runaway (gas, heat, vapors, or smoke) requires fire suppression methods to be applied.The absence of flame is not sufficient to consider the thermal runaway event stopped or extinguished. Large amounts of spray water can be used effectively to cool the battery and contain a lithium-ion battery thermal runaway. In the case of the battery outgassing or after the suppression of the fire, store the battery in a safe place outside for a minimum of 24 hours. We recommend to monitor the temperature frequently to detect any potential new heat generation. In the instance that a thermal runaway reoccurs, follow the same firefighting methods as described above. Operational Data and Limits · Nominal capacity (C1): see Appendix A: RatingsTable. · 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): 1xC1, up to a max of 640 A (limited by charging cable harness[es]). · The permissible truck operation battery temperature range is 14°F (-10°C) to 131°F = (+55°C). · The permissible charge operation battery temperature range is 32°F (0°C) to 122°F (+50°C). · The BMS safely manages current limits based on temperature. · The below table denotes the min and max voltage safety limits allowed by the BMS. Please refer to Appendix A for the rated min and max voltages of the battery packs. Rated Voltage (V) 24 36 48 80 Nominal Voltage (V) 25.55 36.5 51.1 80.3 Min Voltage (V) 19.6 28 39.2 61.6 Max Voltage (V) 29.4 42 58.8 92.4 Environmental Operation Limits · The permissible battery storage temperature range is -40°F (-40°C) to 140°F (+60°C). · The permissible truck operation battery temperature range is 14°F (-10°C) to 131°F (+55°C). · The permissible charge operation battery temperature range is 32°F (0°C) to 122°F (+50°C). · The permissible relative humidity range is 0-95% non-condensing. · EnerSys® Engineering must verify and approve in writing operation of this battery in cold storage applications. 11 HANDLING & INSTALLATION Handling WARNING Batteries are heavy. Ensure secure installation! Use only suitable handling equipment. General Handling Considerations · Unpacking and handling the battery is only allowed by trained personnel that are familiar with the potential risks of lithium-ion batteries and hazardous voltages (voltages greater than 60 volts DC) as applicable for industrial trucks and for lifting heavy loads. · Avoid sudden accelerations, decelerations, drops, and other mechanical abuse conditions while handling the battery. · Handling must only be performed after the battery is disconnected from all electrical loads and charge sources and verified in an OFF state.This can be done using one of the operator interfaces by verifying that the screen and lights are all off when connected to the battery. Voltage across the traction connector may also be checked to ensure contactors are open. · Prior to lifting, secure all connectors and cables so that they will not be crushed, pinched, or otherwise damaged during the lift. User interfaces may be removed prior to handling. · Appropriate PPE must be worn during all lifts. · Appropriate lifting methods and tools that can safely lift and control the load must be checked prior to all lifts.Tools must be properly rated for weight. · If the battery has an outer tray, attach lifting tools to the outer tray lifting points. · The battery must only be lifted vertically. Do not allow the battery to swing during lifting. · The operational and safety instructions of the lifting gear manual must be respected. · If the battery is being handled while installed on a truck, for instance during the battery installation or removal operation, the truck must be secured to prevent movement. Preparing Battery without Outer Tray for Handling* · Remove the sealing bolts from the threaded mounting holes on the inner pack. · Install the EnerSys®-supplied lifting attachments for the battery. · After handling the battery, the lifting interface on the four-point connection on the battery must be removed and the sealing bolts must be fitted again to seal the thread holes.The acceptable torque is based on the bolt size: M8 bolts should be torqued to 34 Nm ± 2 Nm; M12 bolts should be torqued to 66 Nm ± 4 Nm. NOTES: · For transportation and storage safety reasons, all NexSys® iON batteries are shipped at a partial SoC. Before the first operation (refer to page 13: Operation) or further storing the battery (refer to page 17: Storage) it is required to check the SoC (refer to page 7: Operator Interfaces) and recharge the battery if needed (refer to page 14: Battery Charging). · UL HV models only: The battery is equipped with an Emergency Stop Button. It is recommended to push this button prior to handling. Unlock the button before using. * Not applicable for range extension Installation into Industrial Truck Mechanical Installation · This battery is designed to be a drop-in replacement of a lead-acid battery intended to power an electric industrial truck. Modifications of truck firmware, truck settings, or truck hardware may be necessary to accommodate the lithium-ion battery. Consult with industrial truck OEM for required modifications. Depending on the intended application, connectors, ballast, tray size, etc., must be customized to ensure the drop-in compatibility. 12 · Upon receipt of the battery, it must be checked for any obvious signs of damage to both battery and all cables, plugs, and accessories. · Before installation, check that the battery is supplied with the appropriate cable harness to connect the battery to the industrial truck. INSTALLATION & OPERATION Installation into Industrial Truck (cont.) · Ensure that the battery weight and center of gravity requirements per the truck manufacturer are followed. Weight and overall dimensions are listed on the type label located on the battery pack. · The battery must be handled in a way to mitigate the risk of drop events and crashes.The correct tools, lifting points, and method should be used. · After placement of the battery into the truck's battery compartment, the technician must ensure that the battery is mechanically fixed in the truck against the movement as specified by the industrial truck manufacturer. After the battery is fixed in the truck's battery compartment, all cabling must be checked once again in order to ensure that no cables, wires, or plugs have been crushed, pinched, or cut. Electrical Installation · The model number for this battery begins with a 24, 36, 48, or 80 for batteries intended to replace 24 V, 36 V, 48 V, or 80 V nominal lead-acid batteries respectively. · The battery must be connected with the appropriate cables and connector to the industrial truck per the truck manufacturer's recommendation. · Only use EnerSys®-approved fasteners, connectors, cabling, and plugs with this battery. · The cable dimensioning and DC connecting plug will vary depending on the truck and end-user requirements.The truck harness shall comply with relevant requirements for current carrying capability, voltage, and truck interface requirements. Compliance shall be confirmed by the truck OEM. NOTES: · Defective cables and connectors can result in functional issues and/or severe safety hazards such as short circuits and/or fire. Cables and connectors must be regularly inspected for any damage or issues. Cables and connectors should only be repaired or replaced by an authorized EnerSys® representative using the correct factory replacement parts. No substitution is allowed. · HV UL models only: The battery is equipped with an Emergency Stop Button. Unlock this button prior to operation. Operation Anybody using this battery must be trained on the aspects of the battery they are responsible for as required by local laws and regulations. The battery must be handled, operated, stored, maintained, and serviced in accordance with the instructions in this owner's manual. Failure to follow the instructions in this owner's manual can result in serious damage to the battery and may result in serious injury. Failure to follow the instructions in this owner's manual or using parts that are non-original will void the battery warranty. Opportunity charging is highly recommended to maximize the daily run time capability of the battery. It will also optimize the service life of the battery by decreasing the discharge window of the battery. The capability of the battery to power the truck decreases at a low State of Charge (SoC). If the truck is operated at a low SoC, this may result in the battery shutting down with or without a 10-second warning. If this occurs, slowly drive the truck to a matching charger after reactivating the battery. At very low SoC there is a risk of the battery locking out to prevent permanently damaging the cells. If the battery deactivates with a message displayed on the CDI that indicates "Battery Lockout," the pack is locked out and will not turn on again without the visit of a service technician. Contact your EnerSys® Service Representative to inspect the battery to return it to operation. In contrast to lead-acid batteries, it is beneficial to operate this battery at a partial state of charge. The battery temperature influences the capacity of the battery. For example, the run time may be reduced at lower temperatures. Battery temperatures at the extreme ends of the temperature limits as stated in this owner's manual will influence performance, possibly resulting in an unexpected shutdown. Respect all visual and audible warnings from the user interface devices. This battery is designed to be charged indoors in the truck. 13 BATTERY Battery Activation/Deactivation Activation: Activate the battery for truck operation using the push button on any user interface. Provided the pack is not connected to a charger and there are no battery errors, the battery will automatically switch to the traction state, applying power to the truck. In all cases, a short press of about half a second is required. The battery is activated when it is plugged into the charger. This allows battery activation and charging even without previous activation of the battery by other measures above. Deactivation: The battery will deactivate after reaching the default time limit when there is less than a default of 1 A current draw. The default time limit is based on the following battery capacity ranges. Smallest packs (below 25 kWh) timer is set at 4 hours. Medium packs (25 kWh to 53 kWh) timer is set at 24 hours. Large packs (greater than 53 kWh) timer is set at 48 hours. To manually deactivate the battery, press the push button on any user interface for 3 to 5 seconds. Holding for longer may result in turning the pack OFF and then back ON. The industrial truck should be shut down prior to deactivating the battery. NOTE: When deactivating the battery there is a ~20 second shutdown sequence in which an audible alarm will be heard. Pushing the button again during this time will stop the shutdown procedure and return the pack to a fully ON state. If the battery is activated continuously for more than three days, the battery must be connected to a charger (see "Battery Charging" below) or deactivated and afterward activated manually with the above procedure to allow a self-test of safety functions. Emergency Disconnect: HV UL models only: The battery is equipped with an Emergency Stop Button. Pushing this button will disconnect main power from the terminals immediately. WARNING If the battery is locked out due to over-discharge while using (Refer to page 13: Operation) or missed charges during storage (Refer to page 17: Storage) pressing the push button will not power up the traction power, but the BMS and some internal diagnostics. This will discharge the battery even further and may damage the battery irreversibly. Always recharge the battery as soon as possible after reaching low SoC. Battery Charging For industrial trucks driven by an operator, never charge the battery via the traction connector. For AGV applications it is allowed to recharge the vehicle from the harness connected to the truck for discharge and recharge. For charging, the charging plug(s) must be connected to the EnerSys®-approved charger. Unlike in lead-acid batteries, while the battery is installed in the truck, the traction connector of the battery should remain connected to the truck. Upon plugging in the first charge plug, power to the industrial truck is disabled so the truck cannot be operated inadvertently. This battery must only be charged by EnerSys®-approved chargers for lithium-ion, which are specially designed to allow CAN communication with the battery to control the battery recharge.This ensures a safe and optimal operation of the system. All operating instructions found in the owner's manual 14 of the charger must be followed. Charging occurs using an ungrounded separated charging circuit. NOTES: · Never attempt to charge using the connector from the battery to the truck. · NexSys® iON Li-ion batteries will be shipped at or below 30% State of Charge (SoC) to comply with EnerSys® policy on the handling of lithium-ion systems during transport. The battery system is equipped with driveaway protection that will disconnect the traction power, disabling the truck if any battery charging plug is connected to a charger.This mitigates the risk of an operator accidentally driving away when the charger is still connected. CHARGING & SERVICE Battery Charging (cont.) Charge the battery only in an appropriate environment. Additionally, follow all environmental requirements from the charger. · The charge plug has embedded anti-arc contacts to reduce arcing while performing inadvertent hot disconnect operations. NOTES: · In case of an AGV application, the drive-away protection feature might be disabled and must be reset by the truck. · The CAN-enabled charge connector from the battery must be plugged into the matching CAN-enabled charge connector from the charger. Otherwise, the charging will not start as there will be no CAN communication between the battery and the charger. · Depending on the battery, there is dual or single connector charging capability. · At present, communication options such as Ethernet, Programmable Logic Controllers, and remote lights cannot be optioned on the charger. · While installed in the industrial truck, the battery should not be disconnected from the industrial truck to charge, nor is it required to open the lids and covers on the battery compartment. Charging Sequence · Ensure that the battery and charger cables have no damage prior to connecting. · Ensure that connectors are free of contamination prior to connecting. · Connect the charger to the battery charging cable. The battery will either have a single or dual charging cables, depending on the battery model and application charge rate. · Once a charging cable is connected, the traction contactor will open, removing power from the truck for driveaway protection. NOTE: In case of an AGV application, the drive-away protection feature might be disabled and must be realized by the truck.Traction contactor can be always closed. · If the battery is off, the charger will automatically wake the battery and begin to charge. · In case of AGV application the connection with the charger do not ensure the wake up the battery.This depends on the specific application configuration. · Charging will begin after the CAN communication has started between the battery and the charger, which occurs when the charging cable with CAN is connected.The optimal charge current will automatically be determined based on the battery conditions (SoC, temperature, etc.) and charger conditions (temperature, charger size).The charge level will dynamically change during the charging process, ensuring fast charging and ensuring an optimal lifetime of the product. If the battery detects a fault condition, the charging will stop. · If required to stop charging prior to completing the charge, such as during opportunity charging, press the ON/OFF button on the charger prior to disconnecting.The battery must not be disconnected while still being charged by the charger. · After a full charge cycle is complete, the charger screen will indicate that charging is complete. At this point it is no longer supplying current to the battery, and the charge plug(s) should be disconnected from the battery. After completely disconnecting the charge plug(s) the battery will then automatically open the charge path and close the traction path, which will supply power to the truck. · HV UL models only:The battery is equipped with an Emergency Stop Button. Pushing this button will interrupt charging immediately.This is only to be used in emergency situations and may cause errors on the charger or the battery. Service and Maintenance The battery has been designed to be virtually maintenance-free. However, external cabling, connectors, etc. (including operator interfaces) must be regularly examined to ensure there is no damage to such parts and to fulfill local regulations. If any of these parts are damaged or show signs of serious wear, they need to be replaced. Please contact your EnerSys® Service Representative for all repairs and replacements. All repairs must be done by an EnerSys® technician trained on lithium-ion products. 15 SERVICE & TROUBLESHOOTING Service and Maintenance (cont.) All power cables must be checked every time the battery has been exposed to any type of stress, whether it be overvoltage, overcurrent, or mechanical stresses such as crushing. AGV Models: Battery must be turned off and on each year to allow on board contractor diagnostics to run. This is to address the use case differences as AGV application contractors do not cycle daily due to differences in charging strategies. Cleaning Instructions · The exterior of the battery can be cleaned using warm water and an antistatic cloth. · Ensure the battery is deactivated before cleaning. · HV UL models only: The battery is equipped with an Emergency Stop Button. It is recommended to push this button after the shutdown sequence prior to cleaning. This prevents unintentional activation during cleaning. Unlock the button before operation. · 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 turned OFF during charging to prevent driving away from the charger. · Confirm there are no active errors listed on the user interface. In case of errors, review error ID checklist (in the next column). · Inspect power cables to the truck to ensure they are not damaged. · If the battery has OEM integration, check the communication cables between the truck and the battery. · Contact your EnerSys® Service Representative for further troubleshooting steps. · UL HV models only: The battery is equipped with an Emergency Stop Button. Make sure this button is not engaged. Battery will not charge. · Ensure the charger is powered and the charger does not have any errors. In case of an error on the charger, follow the instructions in the charger owner's manual. · 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 there are no active errors listed on the battery user interface. In case of errors, review error ID checklist (in the next column). 16 · Check connectors, auxiliary pins, and CAN cables for damage. · Contact your EnerSys® Service Representative for further troubleshooting steps. · UL HV models only: The battery is equipped with an Emergency Stop Button. Make sure this button is not engaged. No response from the battery when attempting to operate CDI. · Ensure CDI is connected to the Operator Interface Terminal on the battery. · Ensure the communication cable between the battery and CDI is not damaged. · Contact your EnerSys® Service Representative for further troubleshooting steps. Error ID checklist and recommended actions. · View the CDI or E ConnectTM app for the most recent error ID or error IDs. Below is a description of the reason for the displayed error IDs along with corrective actions. · If error ID 401 is displayed, contact your EnerSys® Service Representative as the battery has been locked out and the battery will not operate without a service visit. · If error ID 3 is displayed, ensure the proper shutdown/start-up procedure for the battery and truck is being followed: · 3 Battery shutoff time exceeded due to industrial truck drawing too much current during shutdown of battery. TROUBLESHOOTING & STORAGE Troubleshooting (cont.) · If one or more of the following error ID(s) are displayed, check the power cables and ensure there are no issues with the truck: · 479 Battery short circuit event detected due to external sources. · 7 Battery turning ON while being put under excessive electrical load. · 14 Battery connected to an external device at higher than allowable voltage. · 62 or 63 The current to the truck is excessively noisy. · If one or more of the following error ID(s) are displayed, the battery should be charged: · 39 or 481 Discharge current limit exceeded due to reduced performance limits at low SoC. · 45 or 477 Lower cell voltage limit exceeded. · 49 Lower battery pack voltage limit exceeded. · 70 Lower battery SoC limit exceeded. · 169 Charging is needed due to low SoC. · 39 or 481 Discharge current limit exceeded due to reduced performance limits at temperature extremes. Place the battery in an environment where it can return to normal operating temperatures. · In case any other error ID shows up, please contact your EnerSys® Service Representative for further troubleshooting direction. 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 the SoC has dropped below 30%. The battery must be stored in a dry environment away from fire, sparks, and heat. The allowable storage temperatures are -40°F (-40°C) to 140°F (60°C). To ensure battery health and maximize service life, the maximum temperature of the long-term storage location should be less than 95°F (35°C). The storage area must be compliant with local regulations (including fire, safety, and building regulations) for lithium-ion batteries. The battery must only be stored in an upright position (i.e., 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 there may be trickle discharge. If the battery is removed from the industrial truck for storage and one or more of the harnesses is removed from the battery, the battery terminals must be covered with insulation that can only be removed by the use of a tool, or the battery must be stored in a properly labeled, suitable container that can only be opened by using a tool or key. For storage of greater than one month, precautions must be taken to ensure the battery is not deeply discharged. The pack must be stored at greater than 30% SoC. In addition, processes and recharge methodology must be in place to ensure that the battery does not discharge to 5% SoC in storage. 17 LABELS Battery Label Description Label Type: 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 · Nominal Mass Example of EMEA Type Label Example of AMER Type Label Label Type: Danger Label The danger label, located on the side of the battery, contains warnings critical for the safe usage of the battery. This symbol indicates that the user must to refer to the instruction manual/booklet before use. This symbol indicates that this battery must not be disposed of as unsorted municipal waste. This symbol is used to show that this battery must be recycled and contains lithium-ion. This symbol is used to indicate warning statements. This symbol indicates the risk of electrical shock. 18 SHIPPING & DISPOSAL Shipping Lithium-ion Batteries All persons involved in shipping batteries must comply with all applicable regulations. This battery complies with UN 38.3. Test summaries are available upon request. 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. Because of 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. 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:829515 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. In case of irreparable failure, the battery must be taken out of operation and your EnerSys® Service Representative contacted. 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. 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 NexSys® iON products at specific facilities for disposal. Contact your local EnerSys® Service Representative for specific recycling instructions for your region. 19 APPENDIX Appendix A: Ratings Table The model number for this battery begins with a 24, 36, 48, or 80 for batteries intended to replace 24 V, 36 V, 48 V, or 80 V nominal lead-acid batteries respectively. Model Number 24-L1-20-4.7 24-L1-24-9.5 24-L1-24-14.2 36-L1-40-8.1 36-L1-40-12.2 36-L1-42-12.2 36-L1-42-16.2 36-L1-42-20.3 36-L1-46-16.2 36-L1-46-20.3 36-L1-46-24.3 36-L1-46-28.4 36-L1-48-20.3 36-L1-48-24.3 36-L1-48-28.4 36-L1-48-32.4 36-L1-48-36.5 48-L1-60-7.6 48-L1-60-11.3 48-L1-62-11.3 48-L1-62-15.1 48-L1-62-18.9 48-L1-64-15.1 48-L1-64-18.9 48-L1-64-22.7 48-L1-64-26.5 48-L1-66-18.9 48-L1-66-22.7 48-L1-66-26.5 48-L1-66-30.3 48-L1-66-34.0 48-L1-72-30.3 48-L1-72-34.0 48-L1-72-37.8 48-L1-72-41.6 48-L1-72-45.5 48-L1-72-49.2 48-L1-72-52.9 48-L1-72-56.7 80-L1-80-17.8 Nominal Voltage (V) 25.55 25.55 25.55 36.5 36.5 36.5 36.5 36.5 36.5 36.5 36.5 36.5 36.5 36.5 36.5 36.5 36.5 51.1 51.1 51.1 51.1 51.1 51.1 51.1 51.1 51.1 51.1 51.1 51.1 51.1 51.1 51.1 51.1 51.1 51.1 51.1 51.1 51.1 51.1 80.3 Min Voltage* (V) 21.9 21.9 21.9 28.0 28.0 28.0 28.0 28.0 28.0 28.0 28.0 28.0 28.0 28.0 28.0 28.0 28.0 39.2 39.2 39.2 39.2 39.2 39.2 39.2 39.2 39.2 39.2 39.2 39.2 39.2 39.2 39.2 39.2 39.2 39.2 39.2 39.2 39.2 39.2 67.4 Max Voltage* (V) 28.7 28.7 28.7 42.0 42.0 42.0 42.0 42.0 42.0 42.0 42.0 42.0 42.0 42.0 42.0 42.0 42.0 58.8 58.8 58.8 58.8 58.8 58.8 58.8 58.8 58.8 58.8 58.8 58.8 58.8 58.8 58.8 58.8 58.8 58.8 58.8 58.8 58.8 58.8 90.3 Nominal Energy (kWh) 4.7 9.5 14.2 8.1 12.2 12.2 16.2 20.3 16.2 20.3 24.3 28.4 20.3 24.3 28.4 32.4 36.5 7.6 11.3 11.3 15.1 18.9 15.1 18.9 22.7 26.5 18.9 22.7 26.5 30.3 34.0 30.3 34.0 37.8 41.6 45.5 49.2 52.9 56.7 17.8 Nominal Capacity (Ah) 185 370 555 222 333 333 444 555 444 555 666 777 555 666 777 888 999 148 222 222 296 370 296 370 444 518 370 444 518 592 666 592 666 740 814 888 962 1036 1110 222 Max Continuous Discharging Rate (A) 185 320 320 222 320 320 320 320 320 320 320 320 320 320 320 320 320 148 222 222 296 320 296 320 320 320 320 320 320 320 320 320 320 320 320 320 320 320 320 222 Max Continuous Charging Current (A) 185 370 555 222 333 333 444 555 444 555 640 640 555 640 640 640 640 148 222 222 296 370 296 370 444 518 370 444 518 592 640 592 640 640 640 640 640 640 640 222 20 APPENDIX Appendix A: Ratings Table (cont.) Model Number 80-L1-80-26.7 80-L1-80-35.7 80-L1-82-44.6 80-L1-82-53.5 80-L1-82-62.4 Nominal Voltage (V) 80.3 80.3 80.3 80.3 80.3 Min Voltage* (V) 67.4 67.4 67.4 67.4 67.4 Max Voltage* (V) 90.3 90.3 90.3 90.3 90.3 Nominal Energy (kWh) 26.7 35.7 44.6 53.5 62.4 Nominal Capacity (Ah) 333 444 555 666 777 Max Continuous Discharging Rate (A) 320 320 320 320 320 Max Continuous Charging Current (A) 333 444 555 640 640 * For the Min and Max values acceptable for the pack hardware, please refer to "Operational Data and Limits". Parameter Impulse Withstand Peak Withstand Current (Ipk) Short-time Withstand Current (Icw) Icc Relative Humidity Type of Construction Form of Internal Separation Types of Electrical Connections EMC Classification Macro-environment Designed IP Rating Value 500 2000 1600 100 0-95 Removable Form 1 DDD Environment A Pollution Degree 3 IP54 Unit/Description V A A@1s kA % Non-Condensing No Internal Separation All Disconnectable Industrial 21 APPENDIX Appendix B: Ratings Table Specifically for NexSys® iON Battery Range Extension* The NexSys® iON battery range extension is based on modules that are placed into a tray. The number of modules is determined by the application and the available space. The following module configurations are available: Number of modules 1 2 Nominal Voltage (V) 51.1 51.1 Min Voltage (V) 39.2 39.2 Max Voltage (V) 58.8 58.8 Nominal Energy (kWh) 2.6 5.2 Nominal Capacity (Ah) 51 102 3 51.1 39.2 58.8 7.8 4 51.1 39.2 58.8 10.4 5 51.1 39.2 58.8 13.0 6 51.1 39.2 58.8 15.6 7 51.1 39.2 58.8 18.2 8 51.1 39.2 58.8 20.8 9 51.1 39.2 58.8 23.5 10 51.1 39.2 58.8 26.1 11 51.1 39.2 58.8 28.7 12 51.1 39.2 58.8 31.3 13 51.1 39.2 58.8 33.9 14 51.1 39.2 58.8 36.5 15 51.1 39.2 58.8 39.1 16 51.1 39.2 58.8 41.7 17 51.1 39.2 58.8 44.3 18 51.1 39.2 58.8 46.9 19 51.1 39.2 58.8 49.5 20 51.1 39.2 58.8 52.1 21 51.1 39.2 58.8 54.7 22 51.1 39.2 58.8 57.3 153 204 255 306 357 408 459 510 561 612 663 714 765 816 867 918 969 1020 1071 1122 * 48V range extension, available only in selected regions. Subject to specific application, usage and requirements. Speak to your local EnerSys representative for more information. 22 TERMS AND ABBREVIATIONS Terms and Abbreviations Term/Abbreviation AGVs BDI BMS C1 CDI DC EWS HV IP Rating LV OEM PPE SDS SoC SOH Activated Deactivated Cable Harness Operation Storage Handling Maintenance Service Explanation/Description Automated Guided Vehicles Battery Data Indicator Battery Management System Capacity at one-hour rate of discharge or charge CAN Data Interface Direct Current Early Warning Signal High Voltage (DC > 60 V) Classifies the degree of protection provided by an enclosure for electrical equipment. Low Voltage (may also refer to communication) Original Equipment Manufacturer Personal Protective Equipment Safety Data Sheet State of Charge State of Health In an ON state In an OFF state DC cable and plug that that connects to the industrial truck or battery charger. Refers to charging or discharging the battery. Includes idling of the battery while activated. Refers to the battery being stored. Refers to activities such as lifting, moving, positioning the battery. Includes connecting and disconnecting the charge and power cables. Cleaning the battery and inspection of the battery and connected components (charging cables and user interfaces) for damage. Operations performed by Enersys® representatives to restore the battery to full performance. 23 www.enersys.com © 2025 EnerSys. All rights reserved. Unauthorized distribution prohibited. Trademarks and logos are the property of EnerSys and its affiliates, except Android, iOS, UL, CE, and UKCA, which are not the property of EnerSys. Subject to revisions without prior notice. E.&O.E. GLOB-EN-OM-NEX-ION-0125