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11. MECHANICAL INSTALLATION INTO INDUSTRIAL TRUCK

When substituting a lead acid battery with a Li-ion battery in an industrial truck,
mechanical adjustments of the truck may become necessary. This must be performed
according to the guidance the industrial truck manufacturer or representative has
provided. Before installation, check that the battery is supplied with the appropriate cable
harness to connect the battery to the industrial truck.

Ensure that the battery weight and center of gravity requirements per the truck
manufacturer are followed.

Upon receipt of the battery, it must be checked for any obvious signs of damage to the
battery and all cables, plugs and accessories.

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 (Refer to Section 8:
Handling).

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 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.

12. ELECTRICAL POWER CONNECTION TO INDUSTRIAL TRUCK

The battery must be connected with the appropriate cables and connectors to the
industrial truck per truck manufacturer’s recommendations. Truck harness to be used is
dictated by the truck OEM and shall be in compliance with all UL 583 / UL 2580 and
EN 1175 requirements for current carrying capability and truck interface requirements.

WARNING

: Installing the battery in a non-compliant truck is a fire risk due to a potential

for improperly sized cable harnesses.

The cable dimensioning and DC connecting plug will vary depending on the truck and
end user requirements.

Connection will come from a single connector that is attached to the internal pack (Refer
to Figure 1: Electrical Interfaces).

NOTE

: 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 correct factory replacement

parts. No substitution is allowed.

13. BATTERY COMMUNICATION INTERFACES WITH CHARGER,

TRUCK AND OPERATOR INTERFACES

There are multiple low power connections required to the outside of the CONTROL
MODULE that must be connected during commissioning, depending on the end user
requirements.

The position of the electrical interfaces on the control module is shown in Figure 1:
Electrical Interfaces.

LV Charge Interface

: This is a required connection for all batteries. This interface

connects the Charge Adapter to Control Module allowing for the required CAN
communication between the battery and the charger.

Truck Interface

: This 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.

• 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 10s before

battery shutdown.

• External Key Signal: Truck key actuation allows the turning on of battery.

13. BATTERY COMMUNICATION INTERFACES WITH CHARGER,

TRUCK AND OPERATOR INTERFACES (CONTINUED)

NOTE

: In case use of this signal as interface with the truck is necessary and it was not

previously discussed with EnerSys, please contact service for support as prequalification
and a specific cable are required.

Operator Interface

: Connection point for Y-harness that connects to CAN Data Interface

(CDI) and the optional user interfaces (Refer to Section 14: Operator Interfaces).

NOTE

: The current of the interface must not exceed 0.5A.

LV-Debug Interface

: Debug interface used for EnerSys service purposes.

NOTE

: For any unused connector, the threaded cover must be fastened in place to

prevent ingress of foreign material.

14. OPERATOR INTERFACES

All batteries will be supplied with the CDI, which is attached directly to the battery.
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 SOC.
This operator in-truck interface can be either the BDI or the Truck iQ™ smart battery
dashboard. This requirement of an in-truck interface can only be eliminated if full OEM
integration options are utilized allowing the truck’s existing operator interfaces to be
utilized. OEM integrations require prequalification and approval from both EnerSys

and

the truck manufacturer.

All operator interfaces are equipped with a pushbutton in order to ACTIVATE and
DEACTIVATE the battery.

The operator interfaces will emit audible beeping alarms and visual warnings when SOC
limits are reached. 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 (Refer to Section 13: Battery Communication Interfaces).

CDI (CAN Data Interface):

This device is installed on EVERY battery.

The main purpose of the CDI is to control the flow of information from the BMS to
external data platforms including allowing CAN Open connection between the battery
and industrial truck IF the customer decides this option. Using CAN Open connectivity
allows data and warnings to be displayed via industrial truck dashboard instead of
other operator interface devices. Please consult EnerSys on this option, as it requires
engineering consultation and prequalification with the truck OEMs.

In most cases the CDI will be hidden once the battery is installed into an industrial truck.
However, it does feature an ACTIVATION / DEACTIVATION button and LED display to
allow interaction of the battery if accessible or when a battery is outside of industrial
truck.

The buzzer and LED behavior for the CDI is as follows:

• Warning Depth of Discharge (DOD)

ON 0.5 s / OFF 0.5 s

• Alert DOD

ON 0.5 s / OFF 0.5 s (+ red LED)

• BMS error

ON 0.5 s / OFF 0.5 s (+ red LED)

For full truck integration, the CAN open connector must be connected from the CDI to
the truck.

NOTE

: In the cases of full OEM integration, the battery will cease to function if the CDI

or wires to the CDI are broken. Contact Service for repair or replacement.

The CDI data can be read wirelessly through the EnerSys