EnerSys NexSys, Руководство пользователя

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OWNER’S MANUAL FOR
NEXSYS
®
ION BATTERIES
2
TABLE OF CONTENTS
1.
Scope ................................................................................... 2
2.
Operational Data and Limits .............................................. 2
3.
Environmental Operation Limits ....................................... 2
4.
Safety ................................................................................ 2-3
5.
Usage ................................................................................... 3
6.
Safety Venting .................................................................... 3
7.
Fire Extinguising and Emergency Response ................. 3-4
8.
Handling .............................................................................. 4
9.
Battery Architecture .......................................................... 4
10.
Battery and Safety Labeling ...............................................4
11.
Mechanical Installation into Industrial Truck ................... 5
12.
Electrical Power Connection to Industrial Truck .............. 5
13.
Battery Communication Interfaces
with Charger, Truck and Operator Interfaces ................... 5
14.
Operator Interfaces ......................................................... 5-7
15.
CAN-Bus Connectivity ........................................................ 7
16.
Activation / Deactivation of Battery ................................. 7
17.
Charging Battery ............................................................. 7-8
18.
Transport ............................................................................ 8
19.
Storage ............................................................................... 8
20.
Service and Maintenance ................................................. 8
21.
Dismantling ........................................................................ 8
22.
Disposal and Recycling ..................................................... 8
23.
Troubleshooting ............................................................. 8-9
24.
APPENDIX A: List of Batteries ....................................... 10
25.
Terms and Abbreviations ..................................................10
1. SCOPE
The information contained in this document is critical to the safe handling and proper use
of the NexSys
® iON Lithium-ion (Li-ion) battery for powering of electrical industrial trucks.
It contains a global specification of the system as well as related safety measures, code
of behavior, a guideline for commissioning and recommended maintenance. It 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 use.
While EnerSys
®
has used reasonable endeavors towards the application of legal
requirements, this documentation is not legal advice and should not be relied upon as
such. It is the users’ responsibility to ensure the use of the documentation and any
activities related thereto to follow all legal requirements applicable to themselves and
the applications in the respective countries.
This document is also not intended to substitute any training for handling and operating
the industrial truck or NexSys iON battery that may be required by local laws and/or
industry standards. Proper instruction and training of all users must be ensured prior to
any contact with the battery system.
NexSys iON batteries are designed for industrial truck traction applications only. Only
EnerSys approved chargers are to be used to charge NexSys iON batteries.
Refer to the abbreviations and terms at the end of this document.
2. OPERATIONAL DATA AND LIMITS
Nominal capacity: C
1
– see APPENDIX A: List of Batteries
Nominal voltage: 25.55V, 36.50V, 51.10V – see APPENDIX A: List of Batteries
Discharge current (continuous): 1x C
1
[A] up to a max of 320A (limited by traction cable
harness)
2. OPERATIONAL DATA AND LIMITS (CONTINUED)
Max charge current (continuous): 1x C 1 [A] up to max of 640A (limited by charging cable
harness(s))
Rated operational battery temperature range: 14°F (-10°C) to 131°F (55°C)
(battery temperature)
Rated charging battery temperature range: 32°F (0°C) to 122°F (50°C)
(battery temperature)
This battery must not be used under conditions where it becomes immersed in water.
This battery must not be installed on the underbody of an electrical industrial truck.
Usage of this battery in cold store applications must be verified and approved in writing
by EnerSys Engineering.
Storage of this battery at cold temperatures below the battery operating temperature
must not be allowed.
When the products are intended to be stored for a prolonged period of time (more
than one month), product SOC should be between 30%-70%SOC and optimal storage
temperature should be lower than 35°C.
Product is neither intended to be permanently stored, nor used exclusively outdoors
unless truck is designed for it.
The battery is designed to be charged indoors and while in the truck.
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 NexSys iON battery
warranty.
These batteries are virtually maintenance-free.
Only EnerSys approved fasteners, connectors, cabling and plugs are to be used.
3. ENVIRONMENTAL OPERATION LIMITS
The battery (excluding harness) is rated to IP54, therefore do not clean the battery with
pressurized water.
Do not use the battery outdoors without suitable weatherproof protection.
The battery must not be operated or stored in conditions where it can get immersed.
The battery storage temperatures are -40°F (-40°C) to 140°F (60°C).
The battery operating temperatures are 14°F (-10°C) to 131°F (55°C).
Keep the battery away from fire, sparks and heat.
Battery must not be exposed to extend periods of direct sunlight that allow the
temperature of the battery to rise above the storage and operating temperatures of the
battery.
Batteries must not be operated in condensing environments.
4. SAFETY
This battery is designed to be a drop-in replacement of a lead-acid battery used to
power an electric industrial truck. Modifications of truck firmware, truck settings
or truck hardware may be necessary with the substitution of the lead acid battery
to accommodate the Lithium-ion battery. Consult with Truck OEM for required
modifications. Depending on the intended application, connectors, ballast, tray size, etc.,
must be customized in order to ensure the drop-in compatibility. The instructions of the
operational manual of the industrial truck must be followed.
WARNING
: Installing the battery in a non-compliant truck is a fire risk due to a potential
for improperly sized cable harnesses (Refer to Section 12: Electrical Power Connection
to Industrial Truck for full compliance requirements).
Each battery is designed to be stable and tolerant to the applications within the scope
laid out in the operating conditions, however, battery systems have an inherent hazard
due to the nature of stored energy.
All limits of the vehicle including operating and handling for the vehicle must be followed
in addition to the battery limits as documented in the following sections for a safe
operation, handling and storage.