EnerSys NexSys iON User manual

OWNER’S MANUAL
www.enersys.com
UL Listing applies in the
United States and to certain
models only.

CONTENTS
Introduction ...................................... p. 3
Product Application.......................... p. 4
Battery Architecture.......................... p. 4
Operator Interfaces........................... p. 6
Safety................................................. p. 8
Fire Event Guidance ......................... p. 9
Operational Data and Limits............ p. 10
Environmental Operation Limits..... p. 10
Handling ............................................ p. 10
Installation into Industrial Truck ...... p. 11
Operation .......................................... p. 12
Activation/Deactivation of Battery . p. 12
Battery Charging............................... p. 13
Service and Maintenance ................ p. 14
Troubleshooting................................ p. 15
Storage .............................................. p. 16
Description of Battery Labels .......... p. 16
Shipping Lithium-ion Batteries ....... p. 17
Disposal and Recycling .................... p. 18
Appendix A: Ratings Table................ p. 18
Terms and Abbreviations ................. p. 20
2

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. It contains
a global system specication 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 of these 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 theTerms 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
www.experiencenexsys.com
Your Safety and the Safety of Others is Very Important
wWARNING You may be seriously injured if you don’t
follow these and other related instructions.
INTRODUCTION
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 certication or EN 1175 and EN
60204-1 for CE and UKCA certication).Truck
harness compliance with relevant standards shall
be conrmed by the truck OEM and/or integrator.
wWARNING Installing the battery in a
non-compliant truck is a re 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 tray of the battery in Figure 2.
Figure 1: OuterTray Features
Figure 2: InnerTray Features
Figure 3: Details of the Electrical Interface
Figure 1
Figure 2
OuterTray Lifting Points
(same as other side)
Outer Tray
Cabling for Truck
Power Connection
Outer Tray Lid
Outer Tray
Type Label
Marking of
Weight on
Outer Tray
(AMER Battery
only)
Outer Tray
Battery Vents
Outer
Tray Safety
Label
Optional
Positioning
for Charge
Power
Connection
(multiple
around the tray)
Electrical Interfaces
on Cover of
Control Module
CDI
Y-Harness for
User Interface
Inner Tray
Lifting Points
(same on
other side)
Cabling
for Charge
Power
Connection
InnerTrayType
Label (under
plugs, same as
other side)
Inner Tray
Battery Vent
Steel
Inner Tray
Inner Tray
Safety Label
Figure 3
Protective Covers
(only if no cable is attached)
Truck Terminals
Truck Interface Jumper
(blue plug in the Truck
Interface Terminal, not shown)
Truck Interface
Terminal
(threaded cover if no
cable is attached)
Low-Voltage
Debug Terminal
(threaded cover if no
cable is attached)
Operator
Interface
Terminal
(threaded cover if no
cable is attached)
Charge Terminals Low-Voltage Charge
Interface Terminal
(threaded cover if no cable is attached)
4

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
congurations 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-qualied 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-qualied 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 tray to provide mechanical
protection for the battery
Low-Voltage Interface Terminals:There are
multiple low-voltage 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.
Truck Interface Terminal: This optional interface
provides the possibility to provide specic
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 discreet signal to the truck 10 seconds before
battery shutdown.
• External Key Signal: If implemented, truck key
actuation allows the turning on of the battery.
• Jumper: If installed, do not remove the cap on
this connection as this may result in the battery
no longer operating.
• 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
prequalication and a specic cable are required.
Operator Interface Terminal: Connection point for
Y-harness that connects to CAN Data Interface (CDI)
and the optional user interfaces.
The low-voltage interfaces are protected by a
0.5 A fuse.
Low-Voltage Debug InterfaceTerminal: 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.
5

OPERATOR INTERFACES
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 iQ™ smart
battery dashboard.
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 prequalication 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 4: CAN Data Interface (CDI)
The main purpose of the CDI is to control the
ow 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 prequalication with the industrial
truck OEMs.
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 EnerSys®E Connect™
app available on both iOS®and
Android™ platforms. Contact your
EnerSys®Service Representative for
login details.
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 indicated
low SoC will ultimately result in the deactivation
of the battery due to low SoC.The BDI must be
permanently and securely xed in a position for the
operator to view the BDI for information and access
the button.
Figure 4
Battery Cable
ON/OFF Button
Display Screen Truck Communication Cable (CAN)
6

OPERATOR INTERFACES
Operator Interfaces (cont.)
Figure 5: Battery Discharge Indicator (BDI)
Figure 6: State of Charge Indicator Logic on BDI
Truck iQ™ Smart Battery Dashboard:
Figure 7: Truck iQ™ Smart Battery Dashboard
Truck iQ™:TheTruck iQ™ smart battery dashboard
is an operator interface that provides operators with
more detailed battery information.TheTruck iQ™
device includes the activation/deactivation button,
audible alarms, and visual alarms.TheTruck iQ™
device must be installed per the installation
instructions provided with theTruck iQ™ smart
battery dashboard.TheTruck iQ™ device must be
permanently and securely xed in a position for
the operator to view the information and access the
button.
Refer toTruck iQ™ smart battery device manual for
further information.
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.
Figure 7
Figure 5
Figure 6
Buzzer
Button
Display
State of Charge Indicator
Activation Button
SoC Low SoC
or Error
100% <75% <50% <25%
7

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 re control
and protection per local requirements, including local
re regulations.
• Operate only in monitored areas with suitable re
control and protection per local requirements,
including local re regulations.
• Do not customize the battery hardware or software as
supplied by EnerSys®.
• Only operate with EnerSys®-approved interface
devices.
• Service of the battery must only be performed by
EnerSys®-approved technicians.
• Dismantling the battery is not authorized except by
qualied 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 battery in condensing environments.
• Do not clean the battery with pressurized water.
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
ash of infrared, visible, and ultraviolet light. Molten
and vaporized metal may be ejected.Toxic fumes may
be released. Components may become extremely hot.
Interoperation withTruck 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.
8

SAFETY & FIRE GUIDANCE
Safety (cont.)
• The weight and size of the battery make the battery
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.
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.
If there is an irritation of the respiratory tract, seek
immediate medical attention.
Fireghting operations must be performed based on
guidance provided in the Lithium-ion Battery (Module)
SDS:829515 by trained reghters 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 re suppression methods
to be applied.The absence of ame is not sufcient
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 re, store the battery in a safe place
outside for a minimum of 24 hours. It is recommended
to monitor the temperature frequently to detect
any potential new heat generation. In the instance
that a thermal runaway reoccurs, follow the same
reghting methods as described above.
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 re. If this occurs the battery may release jets
of hot, ammable, corrosive, and toxic liquids/gases,
smoke containing components such as hydrouoric
acid and carbon monoxide.
• In case of battery re, evacuate all personnel from the
area and follow the guidance in the Fire Extinguishing
section of this manual.
• 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.
Additional information can be found in the Safety Data
Sheet for the Lithium-ion Battery (Module) SDS:829515.
9

LIMITS AND HANDLING
Operational Data and Limits
• Nominal capacity (C1): see Appendix A: Ratings
Table.
• Nominal voltage: see Appendix A: RatingsTable.
• 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.
Handling
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 veried 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.
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.
10

HANDLING AND INSTALLATION
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. Modications
of truck rmware, truck settings, or truck
hardware may be necessary to accommodate the
lithium-ion battery. Consult with industrial truck
OEM for required modications. Depending on
the intended application, connectors, ballast, tray
size, etc., must be customized to ensure the
drop-in compatibility.
• 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.
• 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 xed in the
truck against the movement as specied by the
industrial truck manufacturer. After the battery
is xed 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 and truck interface requirements.
Compliance shall be conrmed by the truck OEM.
NOTE: Defective cables and connectors can result
in functional issues and/or severe safety hazards
such as short circuits and/or re. 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.
Handling (cont.)
Preparing Battery without Outer Tray for Handling
• Remove the sealing bolts from the threaded
mounting holes on the inner tray.
• 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 tted
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.
NOTE: For transportation and storage safety
reasons, all NexSys iON batteries are shipped at a
partial SoC. Before the rst operation (refer to page
12: Operation) or further storing the battery (refer
to page 16: Storage) it is required to check the SoC
(refer to page 6: Operator Interfaces) and recharge
the battery if needed (refer to page 13: Battery
Charging).
11

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 benecial to
operate this battery at a partial state of charge.
The battery temperature inuences 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 inuence 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.
Activation/Deactivation of Battery
The battery will deactivate automatically when a
no-load condition is detected for a default setting
of 8 continuous hours to ensure that an unused
battery is not deeply discharged.
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 a default of 8 hours
when there is less than a default of 3 A current
draw. If different values for these are desired,
contact your EnerSys®Service Representative to
make the changes.
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.
12

BATTERY CHARGING
Battery Charging
Never charge the battery via the traction connector.
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 rst 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 of the charger must
be followed. Charging occurs using an ungrounded
separated charging circuit.
NOTE: Never attempt to charge using the
connector from the battery to the truck.
NOTE: 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.
• 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.
NOTE: 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 a 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.
Activation/Deactivation of Battery (cont.)
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.
wWARNING If the battery is locked out due
to over-discharge while using (Refer to page 12:
Operation) or missed charges during storage (Refer
to page 16: 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.
13

CHARGING AND SERVICE
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 fulll 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.
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.
Cleaning Instructions
• The exterior of the battery can be cleaned using
warm water and an antistatic cloth.
• Ensure the battery is deactivated before cleaning.
• Do not clean the battery with pressurized water.
Battery Charging (cont.)
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.
• If the battery is OFF, the charger will
automatically wake the battery and begin to
charge.
• 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.
14

TROUBLESHOOTING
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.
• Conrm 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.
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.
• Conrm there are no active errors listed on the
battery user interface. In case of errors, review
error ID checklist (in the next column).
• Check connectors, auxiliary pins, and CAN cables
for damage.
• Contact your EnerSys®Service Representative for
further troubleshooting steps.
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 EnerSys®E Connect™ 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.
• 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.
15

STORAGE AND LABELS
Storage
During storage, it is recommended to turn the pack
ON at least every six months to conrm SoC has not
dropped below 30% SoC. Recharge to greater than
30% SoC if the SoC has dropped below 30% SoC.
The battery must be stored in a dry environment
away from re, 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 re, 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 use of 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.
Description of Battery Labels
LabelType:
The type label, located on the side of the inner tray
displays important information about the battery,
including:
• Manufacturer Name & Logo
• Part & Serial Number
• Nominal Voltage
• Nominal Capacity
• Nominal Mass
Example of
AMER Type Label
Example of
EMEA Type Label
16

RECYCLING AND TERMS
Description of Battery Labels (cont.)
LabelType:
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 has
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.
Shipping Lithium-ion Batteries
All persons involved in shipping batteries must
comply with all applicable regulations.
All persons involved in shipping batteries must
be trained as required by local regulations to ship
hazardous goods.
Unpacking and packing of batteries shall only be
performed by electrically trained personnel.
Because of their inherent stored energy and
ammability, lithium-ion batteries are considered
“Dangerous Goods” and must be transported in
accordance with all regulations.The classication
for the battery is Class 9, according to UN
“Recommendations on theTransport 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.
17

SHIPPING AND DISPOSAL
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 damages
being assessed.
Do not dismantle, incinerate, or crush battery
systems.
Dismantling the battery is not authorized except by
qualied EnerSys®personnel due to the numerous
hazards involved with dismantling a lithium-ion
battery.
In case of irreparable failure, the battery must be
taken out of operation and your EnerSys®Service
Representative contacted.
Due to the risks posed by damaged lithium-ion
batteries, damaged lithium-ion batteries require
specialized handling and recycling. Do not dispose
of this battery as unsorted municipal waste.
EnerSys®, in line with local regulations, will accept
NexSys®iON products at specic facilities for
disposal. Contact your local EnerSys®Service
Representative for specic recycling instructions
for your region.
Shipping Lithium-ion Batteries (cont.)
This battery complies with UN 38.3.Test summaries
are available upon request.
Damaged batteries must be transported based on
all applicable regulations for damaged lithium-ion
batteries.These requirements are in addition to the
standard UN 38.3 criteria. Contact your EnerSys®
Service Representative for assessment and support
in transporting damaged batteries.
For further transport and regulatory information
(USA and EU; classications and labeling) refer
to Lithium-ion Battery (Module) SDS:829515
instructions or regulations by the International
Civil Aviation Organization (ICAO), International
AirTransport 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.
Appendix A: Ratings Table
Model Number
Nominal
Voltage (V)
Min Voltage
(V)
Max Voltage
(V)
Nominal
Energy (kWh)
Nominal
Capacity (Ah)
24-L1-20-4.7 25.55 19.6 29.4 4.7 185
24-L1-24-9.5 25.55 19.6 29.4 9.5 370
24-L1-24-14.2 25.55 19.6 29.4 14.2 555
36-L1-40-8.1 36.5 28.0 42.0 8.1 222
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.
18

APPENDIX
Appendix A: Ratings Table (cont.)
Model Number
Nominal
Voltage (V)
Min Voltage
(V)
Max Voltage
(V)
Nominal
Energy (kWh)
Nominal
Capacity (Ah)
36-L1-40-12.2 36.5 28.0 42.0 12.2 333
36-L1-42-12.2 36.5 28.0 42.0 12.2 333
36-L1-42-16.2 36.5 28.0 42.0 16.2 444
36-L1-42-20.3 36.5 28.0 42.0 20.3 555
36-L1-46-16.2 36.5 28.0 42.0 16.2 444
36-L1-46-20.3 36.5 28.0 42.0 20.3 555
36-L1-46-24.3 36.5 28.0 42.0 24.3 666
36-L1-46-28.4 36.5 28.0 42.0 28.4 777
36-L1-48-20.3 36.5 28.0 42.0 20.3 555
36-L1-48-24.3 36.5 28.0 42.0 24.3 666
36-L1-48-28.4 36.5 28.0 42.0 28.4 777
36-L1-48-32.4 36.5 28.0 42.0 32.4 888
36-L1-48-36.5 36.5 28.0 42.0 36.5 999
48-L1-60-7.6 51.1 39.2 58.8 7. 6 148
48-L1-60-11.3 51.1 39.2 58.8 11. 3 222
48-L1-62-11.3 51.1 39.2 58.8 11. 3 222
48-L1-62-15.1 51.1 39.2 58.8 15.1 296
48-L1-62-18.9 51.1 39.2 58.8 18.9 370
48-L1-64-15.1 51.1 39.2 58.8 15.1 296
48-L1-64-18.9 51.1 39.2 58.8 18.9 370
48-L1-64-22.7 51.1 39.2 58.8 22.7 444
48-L1-64-26.5 51.1 39.2 58.8 26.5 518
48-L1-66-18.9 51.1 39.2 58.8 18.9 370
48-L1-66-22.7 51.1 39.2 58.8 22.7 444
48-L1-66-26.5 51.1 39.2 58.8 26.5 518
48-L1-66-30.3 51.1 39.2 58.8 30.3 592
48-L1-66-34.0 51.1 39.2 58.8 34.0 666
48-L1-72-30.3 51.1 39.2 58.8 30.3 592
48-L1-72-34.0 51.1 39.2 58.8 34.0 666
48-L1-72-37.8 51.1 39.2 58.8 37.8 740
48-L1-72-41.6 51.1 39.2 58.8 41.6 814
48-L1-72-45.5 51.1 39.2 58.8 45.4 888
48-L1-72-49.2 51.1 39.2 58.8 49.2 962
48-L1-72-52.9 51.1 39.2 58.8 52.9 1036
48-L1-72-56.7 51.1 39.2 58.8 56.7 1110
80-L1-80-17.8 80.3 61.6 92.4 1 7. 8 222
80-L1-80-26.7 80.3 61.6 92.4 26.7 333
80-L1-80-35.7 80.3 61.6 92.4 35.7 444
19

APPENDIX/ TERMS & ABBREVIATIONS
Terms and Abbreviations
Term/Abbreviation Explanation/Description
BDI Battery Data Indicator
BMS Battery Management System
C1Capacity at one-hour rate of discharge or charge
CDI CAN Data Interface
DC Direct Current
LV Low Voltage (may also refer to communication)
OEM Original Equipment Manufacturer
PPE Personal Protective Equipment
SDS Safety Data Sheet
SoC State of Charge
SOH State of Health
Activated In an ON state
Deactivated In an OFF state
Cable Harness DC cable and plug that that connects to the industrial truck or battery charger.
Operation Refers to charging or discharging the battery. Includes idling of the battery while activated.
Storage Refers to the battery being stored.
Handling Refers to activities such as lifting, moving, positioning the battery. Includes connecting and
disconnecting the charge and power cables.
Maintenance Cleaning the battery and inspection of the battery and connected components (charging
cables and user interfaces) for damage.
Service Operations performed by Enersys®representatives to restore the battery to full performance.
Appendix A: Ratings Table (cont.)
Parameter Value Unit/Description
Impulse Withstand 500 V
Peak Withstand Current (Ipk) 2000 A
Short-time Withstand Current (Icw) 1600 A@1s
Icc 100 kA
Relative Humidity 0-95 % Non-Condensing
Type of Construction Removable
Form of Internal Separation Form 1 No Internal Separation
Types of Electrical Connections DDD All Disconnectable
EMC Classication Environment A Industrial
Macro-environment Pollution Degree 3
Designed IP Rating IP54
20