FLUX POWER LiFT Pack X80 User manual
LiFT Pack X80
User Guide
Part # 990993 v1.0
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LiFT Pack X80 User Guide
Safety Precautions
The Flux Power LiFT Pack is a lithium-ion battery and is classified as Class 9 (miscellaneous) Hazardous Material.
Precautions to correctly handle the Flux Power Lithium Battery include:
•The battery should only be handled by authorized personnel familiar with handling, storing and installation of a
Lithium Battery.
•Do not open the battery Only authorized technicians should perform service on a Lithium Battery.
•Do not mount or store the battery upside down or on its side.
•Upon receipt, check the battery for damage during transportation.
•Always use a lifting device when installing a battery.
•Never recycle lithium-ion batteries with lead-acid batteries, please consult Flux Power or your local recycler for
more information on how to recycle a Lithium Battery.
•WARNING Risk of Fire No User Serviceable Parts
Please also refer to the Safety and Reliability Section of this User manual for more information.
IMPORTANT WARRANTY NOTICE
PROPERLY MAINTAINING THE BATTERIES CHARGE AND STORAGE
Allowing the battery to discharge below 24V, extended use or storage after the low SOC alarm goes off due to non-
- will no longer charge. Failure to
properly maintain the battery will void the battery’s warranty.
For technical assistance and additional troubleshooting and technical documentation visit our website at
www.fluxpower.com. Support is also available at 877-505-3589 or support@fluxpower.com.
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LiFT Pack X80 User Guide
Table Of Contents
1. .. 4
2. Flux LiFT X49 Basics . 4
2.1 Construction . 4
2.2 Initial Startup . 5
2.2.2 Truck Integration
2.3 Charging 6
2.3.1 Opporturnity Charging ... 6
2.4 Battery Management Sy. 6
6
6
2.6 Option7
7
7
7
3.2 Over- 7
8
8
8
8
8
5.2 Recycle 9
9
9
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LiFT Pack X80 User Guide
1. Introduction
This manual is intended to provide information on how to operate a Flux X-series 80V battery and maximize its
productivity, longevity, and cost saving features.
2. X80 Battery Basics
2.1 Construction
-ion cells, a Battery Management System (BMS), and counterweights (if
needed). The components are encased in a powder coated 10-gauge steel enclosure. A diagram of the Flux X80 battery
and its components can be seen in Figure 1.
Figure 1: A diagram of the Flux Power X80 Battery and its internal components.
The lithium-ion cells are large format lithium iron phosphate (LiFePO4) cells. They are clamped together and restrained to
a blade to protect against shock and vibration. The cell interconnections are flexible bus bars providing solid and vibration
resistant connections.
Refer to the data plate for the service weight of the battery.
Battery Management System
(BMS)
Battery Leads
Battery Blade
Connections
Current Sensor
Main Contactors
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LiFT Pack X80 User Guide
2.2 Initial Startup
To turn the battery on, press the power button. A green light will illuminate indicating the battery is on. The battery will
click and take approximately 1-5 minutes before it can be charged or used.
Figure 2: ON/OFF switch located on the charge port side of battery.
The battery should be plugged in until fully charged and should remain plugged in or be turned off until installation and
deployment in equipment. There is no danger of overcharging the battery as the onboard Battery Management System
(BMS) communicates with the external charger and efficiently charges and balances the cells. It is important to turn the
battery off if it is not in use and awaiting deployment.
To maintain battery health, keep the battery plugged in whenever it is not in use. Should you completely discharge the
battery, plug the battery in for charging immediately after use. This will help maintain optimum battery health.
2.2.1 Installation
To install safely:
1. Use an approved lifting device and chains (or straps) to lift the battery using the handle cutouts on each side.
2. Slowly place the battery into the battery compartment with the battery power cables oriented appropriately to the
ground support truck.
3. Connect the battery main power cables and communication cable (if applicable) to the truck.
2.3 Charger
Use only a Flux Power approved charger for charging of all X80 batteries. Contact Flux Power for a list of approved
chargers.
On/Off
button
External Charging
Port
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LiFT Pack X80 User Guide
2.3.1 Charging
When charging the battery, consider the following:
Connect the charger to the charging port Euro A320 receptacle.
Do not leave the battery exposed to direct sunlight during charging as this may cause excessive heating.
The charge current must not exceed 350A.
The battery is not intended to be removed for charging.
Opportunity charging during breaks, at the end of a shift, or when the truck is not being used is encouraged. Extended
charging will not harm the battery. Check the truck SOC meter for the status of the battery. If the battery is below 10%
SOC, charge immediately.
2.3.2 Discharging
When discharging the battery consider the following:
The battery will operate from --
The battery should remain on (green light lit) during the entire life of the battery. The only exception is when the
battery will not be in use for more than 2 weeks.
The battery does not require regular maintenance.
2.4 Battery Management System (BMS)
The Battery Management System (BMS) monitors and protects battery life and ensures the battery is performing as
expected by controlling different features including heaters, fans, and charging events as needed.
2.4.1 Cell Balancing
Cell balancing is managed by the BMS and is automatically performed whenever the battery is near the end of the charge
cycle. This feature is intended to keep the cells balanced, giving the user the most power available to the pack.
2.4.2 State of Charge (SOC) Gauge
The primary function of the SOC gauge is to display the amount of energy in the battery. When the battery is not charging,
the SOC gauge will be steadily illuminated and display the SOC of the battery. When charging, the SOC LEDs will
illuminate in sequence indicating it is charging. Once all six (6) lights are steadily illuminated, the pack is fully charged and
balanced. When the battery reaches 20% SOC, a beeper will sound notifying the operator the battery must be charged. If
pack use continues, the battery will beep again at 5% SOC and the BMS will cut power to the lift truck to protect the cells
in the battery. The battery must be charged immediately.
2.5 Temperature
Flux X80 batteries without the heater option have an operational ambient temperature range of 0°C / 32°F to 40C / 104°F
when discharging. The BMS will prevent operation outside these temperatures, but a heater option is available for cold
storage and freezing weather applications. Batteries subjected to low temperatures (0°C / 32°F or lower) may experience
decreased performance if not equipped with the heater option.
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LiFT Pack X80 User Guide
2.6 Optional Heaters
The X80 battery can be equipped with integrated heaters that increase the low temperature performance. The battery can
be discharged in temperatures as low as -30°F / -34°C, and charged in temperatures as low as -10°F. The heaters will
keep the cells at a temperature of 40°F for optimal health and operation.
If the battery is left unattended in sub-zero temperatures, the heaters can discharge the battery within 72 hours. The BMS
will protect the battery from over discharge by turning off the heaters at 20% SOC and will remain off until the battery is
plugged in for charging.
2.7 Storage
Do not store the battery upside down or sideways. The electronics use a small amount of energy to manage the battery,
which limits the amount of time it can be stored. Make sure to charge your battery every 6 months while in storage mode.
If the battery is allowed to drain completely, it will damage the lithium-ion cells and void the warranty. It is recommended
the battery be left in storage mode when not in use or in equipment waiting for deployment.
Storage Mode
Always plug the battery in or place it in storage mode when not in use for extended periods of time. To place the battery in
storage mode, turn the battery OFF. Storage mode prevents the electronics from draining the battery and increases
storage time. It is recommended the battery be plugged in and fully charged every six months when being stored.
Batteries should be stored in temperatures above 0°C / 32°F.
3. Troubleshooting
3.1 No Power to Truck
If the truck does not have power with the battery switched to on, the battery may be at a low SOC. To wake the battery up:
1) Cycle power on the pack.
2) You should hear an audible click and power returned to the truck. Once powered on, charge pack immediately.
3) Plug the battery in. It may take up to five minutes for charging to begin.
3.2 Over-Discharged
This battery contains advanced electronics which will slowly drain the battery. If not charged regularly, the pack may over-
discharge causing the electronics to shut down and the contactor opens. Follow the steps in 3.1 No Power to Truck.
Allowing the battery to discharge below 67 volts -
condition and the battery will no longer charge. Failure to properly maintain the batter will void the batteries
warranty. For technical assistance and additional troubleshooting and technical documentation visit our website at
Only authorized technicians can perform service on this battery.
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LiFT Pack X80 User Guide
4. Safety and Reliability
The battery is completely sealed and requires no watering. There is no danger of acid spills or explosive vapors during
normal use.
4.1 Hazardous Material Information
Federal EPA regulations do not consider completely discharged Flux X80 Batteries to be hazardous waste. There are also
no reporting regulations required for Flux X80 Batteries federally (specifically under the Resource Conservation and
Recovery Act of 1976 (RCRA) and the Emergency Planning and Community Right-to-Know Act (EPCRA)). There are
hazmat regulations when shipping lithium-ion batteries, and the shipper must be trained in the proper packaging and
labeling required.
Some state and city regulations differ from federal law. For information on your local regulations contact your local EPA.
Federal regulations are very strict when dealing with lead-acid batteries due to the environmental impacts of heavy metals
(lead) and the inherent dangers present: acid spills, explosive gases, and lead poisoning. A Flux X80 Battery has none of
these dangers, so is not subject to the associated regulations.
4.2 What to do if a Cell Breach Occurs
If a cell breach occurs open the doors and windows to allow ventilation. Do not use water to clean up the electrolyte, but
instead use absorbent material. Place the contaminated rags in a metal bin. Avoid breathing the fumes, and in case of
fire, do not use water, use a type D, CO2, Dry Chemical or foam fire extinguisher. For more information contact Flux
Power or refer to the SDS.
The damaged battery and cleaning materials should be placed in a sealed plastic or steel container and disposed of or
recycled using the measures required by your local EPA.
4.3 Power Washing and Water Submersion
The battery can be used in applications that require power washing. When power washing the battery, make sure the
power inlet plug and the data port plug are both firmly in place. The battery should not be used in equipment where
submersion in water for any amount of time is possible. In the event the battery is submerged, please do not attempt to
use or charge the battery. Contact Flux Power Support.
5. Recycling/Disposal
5.1 Disposal
Lithium-ion batteries are not specifically discussed in the Federal Resource Conservation and Recovery Act (RCRA).
However, given the federal requirements for hazardous materials, a completely discharged lithium iron phosphate cell is
considered non-hazardous material. States and cities may have more stringent regulations in place, some of which
blanket all lithium-ion batteries as hazardous waste, while others classify them as normal waste. The Flux X8 Battery End
of Life Guide and Guarantee ensures full compliance with laws and the highest environmental standards. The guide is
available and can be requested by contacting Flux Power Support.
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LiFT Pack X80 User Guide
5.2 Recycle
Lithium-ion batteries are recyclable and there are lithium-ion recycling plants nationwide. Do not include lithium-ion
batteries in shipments of lead-acid batteries being sent for recycling. Sending a lithium-ion battery to a lead-acid recycler
could cause damage to lead- acid recycling equipment and personnel. Contact Flux Power Support if you need
assistance.
6. Shipping Information
When shipping a Lithium Battery, the products are classified as UN 3480 Dangerous goods - Part II - Class 9
(miscellaneous) Hazardous and can only be shipped ground. The battery must be secured to a pallet or in a wooden
in equipment it must be securely installed and protected against heat, short circuit, movement, and accidental activation of
the equipment. Shipping declarations, hazmat shipping documentation, and hazmat shipping training are all required. It is
the responsibility of the shipper to obey all regulations when shipping a Flux X80 Battery.
7. Contact Information
Flux Power, Inc.
2685 South Melrose Drive, Suite A
Vista, CA 92081
www.fluxpower.com
877-505-3589
LiFT Pack X80 User Guide
Part # 990933 v1.0
Flux Power specifications are subject to change.
Copyright 2019 Flux Power
Copyright © 2019 Flux Power, Inc. All rights reserved. Flux Power, the Flux Power Logo and Flux LiFT Pack are registered trademarks or
trademarks of Flux Power, Inc. All other brands and product names are trademarks or registered trademarks of their respective owners. This
information is intended for the use of Flux Power customers only. Any other use without the express written consent of Flux Power, Inc. is strictly
prohibited.
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