Alelion EasyPower EP48460CWT-R3-E User manual

EasyPower User Manual
EP48460CWT-R3-E (1002943)
EP48460CWT-R2-E (1004083)
EP48310CWT-R2-E (1003058)
www.alelion.com

22016-06-09, 1004070-001
Contents
General.................................................................................................................... 3
Safety ...................................................................................................................... 4
Overview ................................................................................................................. 5
Operation ................................................................................................................ 7
Recycling ............................................................................................................... 11
Repair.................................................................................................................... 11
Appendix ............................................................................................................... 12
Declaration of Conformity..................................................................................... 12
Material Safety Data Sheet ................................................................................... 13
Battery Markings................................................................................................... 16
Basic Battery Data
Product no: EP48460CWT-R3-E (1002943)
Battery Type: Li-Ion (NMC)
Nominal Voltage: 51.8 V
Nominal Capacity: 448 Ah
Energy: 23 kWh
Usage Temperature Range: 0°C to +45°C (ideally +15°C to +25°C)
Storage Temperature: -30°C to +45°C (ideally +15°C to +25°C)
Weight: 1170 kg ±5%
Usage: 48 V DC systems
Product no: EP48460CWT-R2-E (1004083)
Battery Type: Li-Ion (NMC)
Nominal Voltage: 51.8 V
Nominal Capacity: 448 Ah
Energy: 23 kWh
Usage Temperature Range: 0°C to +45°C (ideally +15°C to +25°C)
Storage Temperature: -30°C to +45°C (ideally +15°C to +25°C)
Weight: 970 kg ±5%
Usage: 48 V DC systems
Product no: EP48310CWT-R2-E (1003058)
Battery Type: Li-Ion (NMC)
Nominal Voltage: 51.8 V
Nominal Capacity: 308 Ah
Energy: 16 kWh
Usage Temperature Range: 0°C to +45°C (ideally +15°C to +25°C)
Storage Temperature: -30°C to +45°C (ideally +15°C to +25°C)
Weight: 970 kg ±5%
Usage: 48 V DC systems

2016-06-09, 1004070-001 3
EasyPower Lithium Ion Battery
User Manual
Read this User Manual carefully before you use the battery.
Keep the instruction for future reference and also keep the user
manual available for the user of the battery.
Installation is only allowed to be done by authorized personnel.
General
The EasyPower battery consists of lithium-ion type cells and a BMS (Battery Management
System) providing onboard intelligence for charging, discharging and supervision. It is
intended for installation in electric lift trucks and material handling equipment for indoor
use.
This product presents a number of advantages over traditional lead-acid batteries, please
read the instructions carefully and make sure to follow them. This will ensure that you get
maximum benefit of your EasyPower battery.
The EasyPower battery has its own steel enclosure that when it is mounted in the outer steel
tray that includes ballast, is fulfilling the lift truck manufactures recommendations. The
EasyPower battery is designed for a specific lift truck model and cannot and should not be
used anywhere else.
A designated charger shall be used for charging, it is controlled by the EasyPower battery via
the CAN-interface.
The capacity demand when you use a lithium-ion battery is as a rule lower than a
corresponding lead-acid battery. This is due to lower losses during use, better lifetime
properties and the possibility to charge faster and more often.
For more information consult the technical manual or contact your lift truck service
organization or the lift truck manufacturer or the importer in your country. For more
information about the advantages of the EasyPower battery please visit: www.alelion.com

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Safety
As this EasyPower battery is of a lithium-ion type and is used in an environment where there
is a potential risk of confusion with a lead-acid battery, we recommend that all personnel
are informed about the difference of the two systems. This will prevent unsafe handling and
also ensure that you get maximum benefit from the EasyPower battery.
The EasyPower batteries are very safe under normal operation and the onboard intelligence
is designed to prevent hazardous situation even if the EasyPower battery is used outside
normal parameters.
Please observe following warnings before using the battery:
oThe Easy Power battery should only be used in the lift truck it is intended for, the
weight and voltage are stated on the label, and shall be consistent with the
requirements by the lift truck manufacturer. Deviations could damage both the
lift truck and cause injury to personnel.
oDo not use the EasyPower battery if it is damaged. Do not touch damaged parts
and contact service personnel.
oAvoid creating short circuit between the external battery terminals and its
contacts. A short circuit can cause fire and injuries to personnel.
oIn case of fire, flames or smoke from the EasyPower battery;
While driving: stop, turn off lift truck and leave the area.
While charging: stop the charger or remove the charger cable and leave the area.
Call for assistance from the fire department and follow the local fire hazard
protocols. A small fire can be controlled with CO2 fire extinguisher, but a major
fire will require large amount of water.
oThe EasyPower battery shall only be connected to a designated charger that is
configured for charging the EasyPower battery. Do not use any other charger, as
this could risk harming personnel or damage the EasyPower battery.
oOnly use the supplied cables. If the cables are damaged, replacement cables shall
be ordered from the lift truck supplier or its representatives.
oInstallation or removal should only be performed by authorized personnel.
oDo not climb or stand on top of the EasyPower battery.
oDo not open the EasyPower battery and access the inside.
oDo not place foreign objects in or on the battery tray.

2016-06-09, 1004070-001 5
Overview
(topside)
1. Lift truck positive (+) terminal
2. Lift truck communication interface (CAN-bus contact)
3. Charger interface (on the side wall)
4. Lift truck negative (-) terminal
5. Battery Indicator
6. Label with key data
Connection to battery terminals shall be made by M10x20-screws with a torque of 24Nm.
Lifting
Use the proper lift holes and lift
equipment that exerts vertical
load on the fixing points.
5
5
2
2
2
3
3
2
4
2
1
2
2
2
2
6
4
2
2
2
2
5

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Labels
Product code; identifies the battery type
EC 62620
Product
Electrical and technical data
Product number; specifies the exact build
Customers own product number
Nominal weight; with and w/o ballast
Symbols; see back page for more info
Warning label; yellow with black text
Cell designation according to IEC 62620
Serial number; unique for each battery

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Operation
The Easy Power battery has several benefits compared to a traditional lead-acid battery;
noticeable for the operator is the use of separate connection for charging. To eliminate the
risk of ignoring that the charger is connected and drive away, the onboard intelligence will
not allow the lift truck to be moved during charging.
There is also a data communication connector that attaches the battery to the lift truck via a
digital interface. This provides communication about battery status such as SOC (State Of
Charge).
The charging is easy and fast, and you can charge anytime without compromising the life
expectancy as with a traditional battery. There is never any risk for overcharging and several
short charging pauses over a work day can replace a longer charging session, this is the most
effective when using a high powered charger.
Battery Indications
The EasyPower battery is integrated with the lift truck and its status can be read using the
ordinary instrumentation. For more information about how and what battery specific data
that is indicated (State Of Charge, fault codes, etc.) in the lift truck instrumentation, please
refer to the lift truck user manual.
There is an onboard LED-indicator that indicates the EasyPower battery BMS status. The
green LED indicator is located on top of the EasyPower battery.
A quick blink once each second indicates that the EasyPower battery CAN communication is
active and the battery terminals can be activated if this is not prevented by a fault condition.
A blink one (1) to two (2) times every 60 seconds indicates that the EasyPower battery is in
protect mode*, there is no CAN communication and the battery terminals cannot be
activated. *(See the subsection Troubleshooting/Protect Mode)

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Charging
The Easy Power battery utilizes an external charger for charging, the charging interface also
has a CAN-communication link that ensures optimal charging control. For more detailed
information regarding charging and the functionality such as indications and behaviors of
the charger refer to the chargers user manual.
The following chargers are recommended to be used together with the EasyPower batteries
covered by this manual:
oMicropower access MA4551-3616 165A (1004073)
oMicropower access MA4721-3616 260A (1004074)
Connect the charger cable connection to the Easy Power battery charging contact. Make
sure the charger is ready for charging and the charging of the EasyPower battery will start
automatically when communication is established. During the connection the external poles
are deactivated.
When you need to use the system again, stop the charger and remove and the charger cable
from the Easy Power battery.
The EasyPower battery is perfect for opportunity charging, make use of your natural breaks
and periods when lift truck is idle. The EasyPower battery is not damaged by charging little
and often.
The charging time will depend of the output power of the charger and the nominal battery
capacity and the current SOC (State Of Charge) as well as the internal temperature.
Maximum charging current that will be utilized by the battery, regardless of the output
capacity of the charger, are 300A or 1C if the battery capacity is smaller than 300Ah.
Example showing estimated bulk charging time:
0 to 99% SOC:
Charger output: 165A260A
EP48460CWT-R3-E 2,5h 1,5h
EP48460CWT-R2-E 2,5h 1,5h
EP48310CWT-R2-E 1,5h 1h
The charging is recommended to be done in a temperature within +5˚C to +30˚C. Outside
this temperature range, the charging current will be limited, and the charging will take
longer time.
We recommend that you keep the EasyPower battery connected to the charger when not in
use.

2016-06-09, 1004070-001 9
Storage
Please note as all batteries the EasyPower battery has a certain self-discharge, this is mainly
due to power consumption of the inbuilt security system. Never store an EasyPower battery
that indicates or warns that the SOC is low, it should be charged at first given opportunity.
Store less than four (4) weeks; no special consideration needed, the battery should not risk
going to protect* due to self-discharge during this timeframe.
Store more than four (4) weeks; charge until full before the lift truck / EasyPower battery is
put in to storage. Follow this to avoid ending up in protect* mode due to the self-discharge
earlier then needed. Before it is put back in to use, charge again if needed.
*(See the subsection Troubleshooting/Protect Mode)
Control a stored EasyPower battery at least every sixth (6) month and charge if SOC <50%.
Driving
Always use lift truck according to the manufacturer’s instructions. Normal operation should
not be any different for the operator until the EasyPower battery is almost empty. This will
be communicated to the lift truck and it will initiate various limitation actions. This can be as
an example; limited acceleration and/or lower lifting speed. When this occurs you are
driving on the last reserve and therefore should stop working and recharge your Easy Power
Battery.
For more specific information regarding the lift truck limitations when battery capacity
reaches the end, please refer to lift truck user manual.
Maintenance
Maintenance is only allowed to do be done by instructed personnel that have knowledge of
batteries with high energy content.
Once a week:
oControl that the charging connections are undamaged.
oClean if needed, the EasyPower battery shall only be wiped off when cleaning.
Never use flowing water or high pressure cleaning.
Once a month:
oLet the charger be connected to the EasyPower battery until it indicates battery
fully charged, at least once a month to keep it balanced*.
*(After a while with incomplete charging and loading cycles the need for balancing
might occur. This will ensure that all cells are fully charged and that you have all the
capacity at your disposal. The balancing is automatic and is done if needed with help of
the charger, at the end of the charging cycle.)
Remaining maintenance shall be done by service personnel at occasions that follows
ordinary service schedule for the lift truck.

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Troubleshooting
Protect Mode
To protect the user and the hardware connected as well as the EasyPower battery; some
situations can trigger the EasyPower battery to go in to a protect mode. It will then
disconnect the DC output terminals. This can be an indication of a problem, but can also be
triggered by usage outside the normal parameters, or as a last measure to avoid harmful
deep discharge when the battery is close to being fully discharged.
If this is due to a fault in the lift truck it will also be indicated by the lift truck
instrumentation, please refer to lift truck user manual.
To bring the EasyPower battery out of the protect mode, it should be connected to an active
charger or as a second choice if no charger is available, disconnect the cable connector from
the EasyPower battery CAN -bus connector and reconnect. This will if possible reset the
EasyPower battery and bring it out of the protect mode, if this is not prevented by a serious
fault condition.
Faultfinding
If the EasyPower Battery shuts down during use it can be caused by:
oDamaged cables
oBroken fuse
oToo low cell voltage
oToo high or low battery/cell temperature
If this happens make a visual inspection of the EasyPower battery connections, without
removing it from lift truck. Is there any suspicion regarding damaged cables, contact service
personnel. If no damaged cables can be detected visually, proceed with next step.
Put the EasyPower battery on charge in an indoor environment +5°C to +30°C. Wait at least
for one (1h) hour and try to use the EasyPower battery again.
If the EasyPower battery does not start or start and shut down again within one or two
minutes (1-2 min), contact service personnel.
If the EasyPower battery cannot be charged it can be caused by:
oDamaged cables
oToo high or low battery/cell temperature
oThe charger is faulty
If this happens make a visual inspection of the EasyPower battery connections, without
removing it from the lift truck. Is there any suspicion regarding damaged cables, contact
service personnel. If no damaged cables can be detected visually, proceed with next step.
Try another charger, if it still refuses to charge, proceed with next step.

2016-06-09, 1004070-001 11
Remove charger, wait in an indoor environment +5°C to +30°C for four to five (4-5h) hours,
even longer if you suspect that temperature is too high or too low.
Try again to put the EasyPower battery on charge in an indoor environment +5°C to +30°C.
If the EasyPower battery still will not charge, contact service personnel.
If the EasyPower battery charges slowly it can be caused by:
oUnbalanced cells
oToo high or low battery/cell temperature
Charge the EasyPower battery in an indoor environment +5°C to +30°C during at least five
(5h) hours.
If the charger still not indicates that the EasyPower is fully charged, contact service
personnel.
Recycling
The batteries shall be sent back to the importer in the country of usage or be recycled in
accordance with national environmental protection regulations or disposal laws.
Cell designation according to IEC 62620: ICNMP/28/149/95/H/-30+55/95
Observe that during transport the Easy Power battery shall be handled as dangerous goods,
according to UN3480 Class 9.
oThe external terminals shall be protected from short circuit
oNormal or superannuated batteries shall be packed according to P903
Only personnel with training for transport of dangerous goods (1.3 training according to UN
38.3) are allowed to pack and mark the goods.
Repair
If it is necessary to repair the EasyPower battery, some parts can be replaced by the field
service but any fault in the internal parts must be repaired at a service center.
Always contact your service organization*, when the EasyPower battery is suspected to be
faulty and before returning the EasyPower battery. *(same as for the lift truck.)
Observe that during transport the Easy Power battery shall be handled as dangerous goods,
according to UN3480 Class 9.
oThe external terminals shall be protected from short circuit
oDamaged/defective batteries shall be packed according to P908 and LP904
Only personnel with training for transport of dangerous goods (1.3 training according to UN
38.3) are allowed to pack and mark the goods.

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Appendix
Declaration of Conformity
Declaration of Conformity
Manufacturer
Alelion Batteries AB, Flöjelbergsgatan 14C, SE 44934 Mölndal, Sweden
We declare that the product listed below is in accordance with the following Directives:
2004/108/EC EMC Directive
Type of equipment:
Lithium-ion battery
Product type:
1003200 EP48310CWT-CB3-E
1003500 EP48460CWT-CB3-E
1003220 EP48460CWT-CB4-E
1002943 EP48460CWT-R3-E
1003058 EP48310CWT-R2-E
1004083 EP48460CWT-R2-E
1003519 EP24310CWT-O3-E
1003904 EP24260CWT-S3-E
1003860 EP24260CWT-S6-E
EMC standard
SS-EN 61000-6-2:2005 Issue 3
SS-EN 61000-6-3:2007 Issue 2 with SS-EN 61000-6-3/A1: 2011 Issue 1
Date: 2016-02-22 Fredrik Sööder, Director R&D

2016-06-09, 1004070-001 13
Material Safety Data Sheet
Instructions for the Safe Handling of EasyPower Lithium Ion Batteries
Batteries are considered as articles under REACH regulation 1907/2006/EC and, as such, do not require
the publication of a safety data sheet. However, there is a requirement to provide safety information on
products. This document, which fulfils this requirement, is commonly called an MSDS, but, in Europe, is
more correctly referred to as ‘Instructions for the Safe Handling of Lead-Acid Batteries’.
Product and company identification
Product: Traction Lithium Ion Battery
Brand name: EasyPower
Manufacturer: Alelion Batteries AB
Adress: Flöjelbergsgatan 14 C, S-431 37 Mölndal, Sweden
Emergency phone: + 46 31 86 62 00
Composition/information on ingredients
As a solid, manufactured article, exposure to hazardous ingredients is not expected with normal use.
Hazards identification
The battery is not classified as dangerous according to directive 1999/45/EEC.
There is no hazard when the measures for handling and storage are followed.
In case of cell damage, possible release of dangerous substances and a flammable gas mixture can occur.
First Aid Measures
The following first aid measures are required only in case of exposure to interior battery components
after damage of the external battery casing. Undamaged, closed cells do not represent a danger to the
health.
After inhalation: Ensure of fresh air. Consult a physician.
After contact with skin: Wash off immediately with plenty of water. Consult a physician.
After contact with eyes: Rinse immediately with plenty of water, also under the eyelids, for at least
15 minutes. Seek medical treatment by eye specialist.
After ingestion: Drink plenty of water. Call a physician immediately.
Firefighting measures
Suitable extinguishing media: Cold water and dry powder in large amount are applicable.
Special hazards arising from the chemical: May form hydrofluoric acid if electrolyte comes into contact
with water. In case of fire, the formation of the following flue gases cannot be excluded: Hydrogen
fluoride (HF), Carbon monoxide and carbon dioxide.
Protective equipment and precautions: Wear self-contained breathing apparatus and protective suit.
Additional information: If possible, remove battery from firefighting area. If heated above 125 °C,
cell(s)inside the battery can vent.Battery is not flammable but internal organic material will burn if the cell
is incinerated.

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Accidental Release Measures
This information is relevant only if the battery is broken and the contents are released.
Personal precautions Use personal protective clothing. Avoid contact with skin, eyes and clothing. Avoid
breathing fume and gas.
Environmental precautions Do not discharge into the drains/surface waters/groundwater. Take up
mechanically and send for disposal.
Handling and storage
Handling
Avoid short circuit, the battery contains a short circuit fuse.
Avoid mechanical damage.
Don’t open the battery.
Keep fire extinguisher in relevant distance
Keep away from open flames, hot surfaces and sources of ignition.
Storage
Store in-house between -30 ⁰C and + 45 ⁰C, optimum temperature is just below 20 ⁰C fore best life time.
Avoid short circuit.
Place on a pallet for easy removal in case of danger.
Exposure Controls/Personal Protection Exposure limiting values
During normal charging and discharging no release of any hazardous substances occur.
Physical and Chemical properties
Appearance: Form: Solid
Color: Not applicable
Odor: Odorless
Important health, safety and environmental information:
pH value: Not applicable
Flash point: Not applicable
Lower explosion limit: Not applicable
Vapor pressure: Not applicable
Density: Not applicable
Water solubility: Insoluble
Ignition temperature: Not applicable
Stability and reactivity
Stability: Stable
Conditions to avoid: Keep away from open flames, hot surfaces and sources of ignition.
Material to avoid: None
Hazardous decomposition products: In case of fire and open cells, there is a possibility of HF and CO
release.
Possibility of Hazardous Reactions: Will not occur
Additional information: No decomposition if stored and applied as directed.
Toxicological information
If appropriately handled and if in accordance with the general hygienic rules, no damages to health have
become known.

2016-06-09, 1004070-001 15
Ecological information
Ecological injuries are not known or expected under normal use. Do not flush into surface water or
sanitary sewer system.
Disposal considerations
Spent lithium Ion batteries (EWC 16 06 01) are subject to regulation of the EU Battery Directive
(2006/66/EC) and its adoption into national legislation on the composition and end-of-life management of
batteries. Spent batteries are recycled in special approved facilities. The main part of the recycling is
material recycling, but also some energy recycling.
Spent batteries are taken back by the producer or importer.
Transport Information
Land transport (ADR/RID)
UN number: UN3480
ADR/RID class: 9
Classification code: M4
Marking: 9
Tunnel restriction code: E
Description of the goods: LITHIUM ION BATTERIES
Marine transport (IMDG)
UN number: UN3480
IMDG code: 9
Marine pollutant: No
Marking: 9
Description of the goods: LITHIUM ION BATTERIES
Regulatory information
In accordance with the EU Battery Directive and the respective national legislation, lithium ion batteries
have to be marked by a crossed out dust bin. The batteries are marked with some or all of the following
hazard symbols [See back page].
Other information
Release date: 18 February 2014
Revision date: 09 April 2014
Revision: B
Prepared by:
Alelion Batteries AB
Flöjelbergsgatan 14C
431 37 Mölndal, Sverige
The information given above is provided in good faith based on existing knowledge and does not
constitute an assurance of safety under all conditions. It is the user’s responsibility to observe all laws and
regulations applicable for storage, use, maintenance or disposal of the product. If there are any queries,
the supplier should be consulted.
However, this shall not constitute a guarantee for any specific product features and shall not establish a
legally valid contractual relationship.

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Battery Markings
Warning sign
Battery danger; contains battery cells. Avoid short circuit.
Prohibition sign
Do not expose the battery of high temperature.
The EasyPower battery is built for usage up to +45˚C ambient
temperature. By safety reasons the EasyPower battery shall
not be exposed of temperatures above +85˚C.
Information sign
Read the user manual before the EasyPower battery is
installed and used.
Crossed out wheelie bin
Do not dispose as waste, product must be recycled.