Still BG 2.1 B.G 2.2 Lithium-ion batteries 48-V version Workshop Literature Manual - PDF DOWNLOAD

Workshop literature

Lithium-ion batteries 48-V version BG 2.1, 2.2

50988012057 EN - 12/2017

History of changes g Edition 2017/12 • Version 1 • First edition for battery group 2 • This version 1 is continually being extended and replaced by updated versions.

50988012057 EN - 12/2017

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Header g List of abbreviations NOTE

The list of abbreviations provides an overview of the abbreviations used in this document and their definitions. The explanations refer only to their use in this document.

Abbreviation

Meaning

Explanation

AC

Alternating Current

Alternating current

ADR

Accord européen relatif au transport international des marchandises Dangereuses par Route

European convention for the international carriage of hazardous materials by road

Rechargeable battery

Rechargeable battery

Storage medium for electrical energy

BCM

Brake Chopper Module

Brake chopper module

BMS

Battery Management Control Battery Management System

BOL

Begin Of Life

Battery operating life

CAN

Controller Area Network

Serial bus system (CAN bus)

CE

Communauté Européenne

Confirms conformity with product-specific European directives (CE labelling)

BMC

Battery master controller Battery management system

CSC

Commission on the Rules for the Approval of the Electrical Equipment Comité Européen de Normalisation Cell State Controller

CVS

Current Voltage Sensor

Current/voltage sensor

DC

Direct Current

DC/DC

Voltage transformer

Direct current Transducer for potential-free measurement of DC voltage

DIN

Deutsches Institut für Normung

German organisation for standardisation

DOD

Deep Of Discharge

Depth of discharge (energy extracted in relation to capacity

EN

Europäische Norm

European standard

EOL

End Of Life

End of the battery service life

CEE CEN

FEM ID-Nr.

International Commission on the Rules for the Approval of Electrical Equipment European committee for standardisation Battery module controller (slave controller)

Fédération Européene de European Federation of Materials Handling and Storage Equipment la Manutention Unique ID of the object in question Identification number

IP

International ElectrotechniInternational Electrotechnical Commission cal Commission Protection type for electrical operating materials International Protection

LCD

Liquid Crystal Display

IEC

Liquid crystal display (battery display)

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Header g Abbreviation

Meaning

Explanation

LED

Light Emitting Diode(s)

Light emitting diode(s)

max. min.

Maximum Greatest value of an amount Minimum Smallest value of an amount Negative Temperature Negative temperature coefficient Coefficient Persönliche SchutzausrüsPersonal protective equipment tung Règlement concernant le transport international fer- Regulations concerning the international carriage of roviaire de marchandises hazardous materials by rail Dangereuses Parameter for the charging state of a battery (battery State Of Charge charge level) Battery function/performance capability State Of Function Parameter for the health of a battery = residual capacity State Of Health of an old battery (battery degradation) Steuer-SpannungsControl voltage supply Versorgung Ordinance on hazardous materials applicable in the Technische Regeln für Federal Republic of Germany Gefahrstoffe The handling of hazardous materials is determined United Nations by the United nations (UN) and indicated by the UN identification number for hazardous materials.

Verband der Elektrotechnik Elektronik Information- German technical/scientific association stechnik

NTC PSA RID SOC SOF SOH SSV TRGS UN VDE .

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50988012057 EN - 12/2017

Header g Units Unit symbol

Unit name

Explanation

°C

Degree Celsius

Unit of temperature

°F

Degree Fahrenheit

Unit of temperature

A

Ampere

Unit of electrical current

Ah

Ampere hour

Unit of electrical charge storage capacity (nominal capacity)

dB

Decibel

Unit of sound intensity

cm

Centimetre

Unit of length (1 cm = 10 mm)

cm3 g

Cubic centimetres

Unit of volume

Gram Hours per day

Unit of mass Hours driven per day

h/d kg kg/m3 km/h kN

Kilogram Unit of mass (1 kg = 1000 g) Kilograms per cubic metre Unit of density (ratio of the mass of a body to its volume) Kilometres per hour Unit of speed Unit of force (1 kN = 1000 N) Kilonewton

kW

Kilowatt

Unit of electrical power

kWh/h

Kilowatt hour/hour

Energy consumption

l l/h

Litre Litres per hour

Unit of volume Unit of consumption

l/min

Litres per minute

Unit of consumption

m

Unit of length (1 m = 100 cm) Metre Metres per second squared Unit of acceleration Unit of time (1 min. = 60 s) Minute Revolution(s) per minute Unit of revolution speed Unit of length (1 mm = 10-3 m) Millimetre Unit of force (1 N = 10-3 kN) Newton Unit of torque Newton metre

2

m/s min rpm mm N Nm s

t V W W/kg Wh Wh/kg

Second Tonne Volt Watt Watt/kilogram Watt-hours Watt-hours/kilogram

Base unit for time Unit of mass (1 t = 1000 kg) Unit of electrical voltage Unit of electrical power Performance by mass (power density) Unit of electrical work (nominal energy) Stored energy per kilogram of mass (energy density)

.

Glossary Rechargeable battery A rechargeable battery can store electrical energy by converting it into chemical energy and then output this energy by reconverting it. This is how all rechargeable cells or batteries work.

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Header g Active materials Materials in the electrodes in which the chemical alteration processes (charging, discharging) take place are active materials. These are lithium metal oxide and carbon in lithium-ion batteries.

Battery A battery consists of multiple cells that are electrically connected by permanent means, and including housings, connectors and labels.

Examples of batteries: • 9 V monobloc battery • 48 V traction battery • 200 to 800 V hybrid battery (car)

Battery Management System The battery management system (BMS) monitors the discharge and the temperature of the battery. When charging, the BMS ensures balanced charging of the battery cells. It protects the cells and determines the charging state. The BMS consists of the battery module controllers (CSC) within the modules, and the battery master controller (BMC) for the battery.

C-rate The C-rate is the standardised charge current and discharge current in amperes. The C-rate corresponds to the nominal capacity divided by one hour.

Example of 240 Ah nominal capacity: C-rate

Charge/disCharging time charge current

1

240 A

1h

0.5

120 A

2h

0.2

48 A

5h

.

Electrodes The electrodes consist of the active material and the conductors (connections). These are aluminium and copper in lithium-ion batteries.

Energy density The energy density is the ratio of available energy from the battery to its volume or weight.

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Header g Final discharged voltage The final discharged voltage is the voltage at which the discharge of a battery or a rechargeable battery is terminated.

During discharge tests, the final discharged voltage is defined as the voltage below which no usable energy can be extracted for the respective application. In rechargeable batteries, it is the lower limit of the cell voltage for deep discharge.

Rechargeable battery system

Typical final discharged voltage for single cells

Lithium polymer battery

3.30 V

Lithium-ion battery

2.50 V

Lead-acid battery

1.75 V

Nickel-zinc battery

1.20 V

Alkaline manganese battery (rechargeable)

1.0 to 1.10 V

Nickel metal hydride battery

1.00 V

Nickel-cadmium battery

0.85 to 1.00 V

.

Final charged voltage The final charged voltage is a parameter for rechargeable batteries. It describes the voltage applied to the battery terminals as a terminal voltage during the charging process when the battery charger is connected.

The final charged voltage is higher than the nominal voltage.

Charging cycle Charge cycles are the number of discharges followed by re-charging. They are a parameter for rechargeable batteries. A charging cycle corresponds to time it takes for a battery to recharge from the permissible discharge limit of the battery to full charge. The full charge corresponds to an SOC of 100 %. The number of charging cycles always has the same ratio to the number of discharge cycles and is the principal factor determining the ageing of the battery.

Important factors for the number of charge cycles: • Discharge current • Discharge time • Depth of discharge (DOD) • Temperature

Nominal energy The nominal energy (Wh) is the energy in watthours that a battery can output under defined conditions.

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Header g The nominal capacity (Ah) multiplied by the nominal voltage (V) gives the energy content.

Example: 240 Ah x 48.75 V = 11,700 Wh (11.7 kWh)

Nominal capacity The nominal capacity (Ah) is the stored quantity of electricity (current value x time) in a fully charged battery that can be extracted during discharge under defined conditions.

For example: A battery with 240 Ah could output a current of 240 A for one hour or a current of 1 A for 240 hours.

Nominal voltage The nominal voltage (V) is the characteristic operating voltage of the battery.

Example: Battery type

Nominal voltage

Lead-acid cell

2.0 V

Nickel-cadmium cell

1.2 V

Zinc-carbon cell

1.5 V

Lithium-ion cell

3.7 V

.

Memory effect The reduction in capacity caused by frequent partial discharge of nickel-cadmium batteries is known as the memory effect.

Power source parallel connection Parallel connection increases the capacity and the maximum discharge current. Only power sources with the same output voltages can be connected in parallel.

386_000-001

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Header g Primary cell Primary cells (1) are not rechargeable and can be discharged only once.

Power source serial connection The serial connection of power sources increases the total voltage. The capacity remains the same.

386_000-002

Regenerative braking (recuperation) The term recuperation (derived from the Latin recuperare = regain) describes a technical procedure for energy recovery.

Secondary cell Secondary cells are rechargeable.

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Header g Cell The cell is the smallest element of a battery. The size and the voltage produced by the material combination of the electrodes determines its capacity.

A cell consists of an anode, cathode, separator and electrolyte.

Examples of cells: • 1.5 V/3 V button cells • 2 V lead-acid cells • 3.7 V lithium-ion cells • Mono cells (D) • Baby cells (C) • Mignon cells (AA) • Micro cells (AAA) • Mini cells (AAAA)

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50988012057 EN - 12/2017

Table of contents g 00 Product information Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-1 Overview of the battery groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-1 Nameplate of a lithium-ion battery

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-1

Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-2 Special safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-2 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-4 Dangerous misuse

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-4

Procedure in the event of a battery-related accident . . . . . . . . . . . . . . . . . . . . . . . . . . 00-5 Lithium-ion battery: First-aid measures

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-5

Transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-6 Battery transport with crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-6 Transport directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-6 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-7

Description of lithium-ion battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-8 Structural principle of the battery cell

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-8

Charging/discharging - operating principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-8 Advantages of lithium-ion technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-9 Structural principle of the battery module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-10 Temperature sensors

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-13

Battery module LED display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-13 Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-14 Battery display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-14 Battery management system (BMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-16

01 Service Maintenance and repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1 Service plan

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1

Cleaning the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1

Operating materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2 Tools, insulated up to 1000 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2 Personal protection equipment (PSA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-3 Special tool for lithium-ion technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-3 Attaching/removing the lifting tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-4

Battery charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-5 Battery discharge

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-5

Course of action for a deeply discharged battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-6 50988012057 EN - 12/2017

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Table of contents g Function checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-12 Checking that the battery male connector is de-energised . . . . . . . . . . . . . . . . . . . . . 01-12 Insulation testing the lithium-ion battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-13

21 Battery group 2.1 Design BG 2.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-1 Technical data for battery group 2.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-1 Diagnostic set-up

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-2

Design - Battery group 2.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-3 Technology compartment - Battery group 2.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-4

De-energised state BG 2.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-5 Measuring the insulation resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-5 De-energising the technology compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-6 Checking that the technology compartment is de-energised . . . . . . . . . . . . . . . . . . . . 21-9 Restoring operating status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-9

Components BG 2.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-13 Tray cover - Battery group 2.1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-13

Removing/fitting the tray cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-13 Battery display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-15 Removing/installing the battery display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-16 Schocksensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-19 Pressure compensation element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-20 Removing/installing the module holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-21 Removing/installing the positive power connector . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-27 Removing/installing the battery module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-29 CAN bus terminating resistor (120 Ω) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-32

Technology compartment BG 2.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-33 Opening/closing the technology compartment

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-33

Current/voltage sensor (CVS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-35 Removing/installing the current/voltage sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-35 Brake chopper module (BCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-38 Removing/installing the brake chopper module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-40 Brake resistor 105 mΩ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-43 Removing/installing the brake resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-43 Battery master controller (BMC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-46 Removing/installing the battery master controller . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-46 Control voltage supply (SSV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-48 Removing/installing the control voltage supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . 21-48

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Table of contents g Contactor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-50 Removing/installing the contactor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-50 Voltage transformer (DC/DC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-56 Removing/installing the voltage transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-56 Electrical fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-58 Replacing electrical fuses

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-59

Wiring BG 2.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-62 Removing/installing the power cable

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-62

22 Battery group 2.2 Design BG 2.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-1 Technical data for battery group 2.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-1 Design - Battery group 2.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-2 Technical compartment - battery group 1.1 / 1.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-4

De-energised state BG 2.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-5 Measuring the insulation resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-5 Spannungsfreiheit im Technikraum herstellen

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-6

Spannungsfreiheit im Technikraum prüfen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-8 Beriebszustand wiederherstellen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-8

Components BG 2.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-11 Tray cover - Battery group 2.2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-11

Trogdeckel Abbau/Anbau . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-11 Battery display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-13 Batterie-Display Ausbau/Einbau

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-14

Schocksensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-18 Pressure equalising element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-19 Leistungsverbinder Plus Ausbau/Einbau . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-20 Temperature sensors

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-23

Batteriemodul Ausbau/Einbau . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-23 CAN bus terminating resistor (120 Ω) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-26

Technology compartment BG 2.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-28 Technikraum öffnen/schließen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-28 Current/voltage sensor (CVS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-30 Removing/installing the current/voltage sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-30 Brake chopper module (BCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-34 Removing/installing the brake chopper module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-36 Brake resistor 105 mΩ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-38

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XIII

Table of contents g Removing/installing the brake resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-38 Battery master controller (BMC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-42 Removing/installing the battery master controller . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-42 Control voltage supply (SSV) with reset button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-44 Removing/installing the control voltage supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . 22-44 Contactor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-46 Removing/installing the contactor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-46 Voltage transformer (DC/DC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-52 Removing/installing the voltage transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-52 Electrical fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-55 Replacing electrical fuses

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-56

Wiring BG 2.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-59 Removing/installing the power cable

XIV

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-59

50988012057 EN - 12/2017

Product information

00

a

Foreword Overview of the battery groups Truck

Available energy Capacity

Circuit

Tray no.

13.1 kWh 268 Ah 48.9 kWh 1005 Ah

B

315

Tray dimensions [mm] Length

Width

Height

1030

529

350

1030

529

627

Battery group 2 2.1 2.2

RX20 14-20

48 V

.

Nameplate of a lithium-ion battery 1

Manufacturer

2

Nameplate

3

Address of manufacturer

4

Safety information

5

Data matrix code

6

Transportation notes

7

General operating notes

8

CE labelling

9

Data/technical data

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00

Product information

Safety information Special safety regulations Special safety regulations must be observed for lithium-ion batteries. An industrial truck with lithium-ion-battery must be identified accordingly with a lithium-ion label.

Special safety instructions

All lithium-ion batteries are essentially associated with the risk of a fire starting, of the battery exploding and of the battery causing chemical burns. The escape of dangerous substances from the enclosed battery tray can be excluded only by correct use and safe handling. The risk of contact with toxic or corrosive substances exists only in cases of improper handling leading to safety valves being opened or the housing being breached. These can result in electrolyte escaping, electrode materials reacting with moisture and water, or fire and explosion.

External temperatures of >80 °C can cause the battery to explode.

The following guidelines must be observed: – Observe the manufacturer’s information on Linde lithium-ion technology.

– Only work on the battery in areas that can be easily ventilated in the event of an emergency.

– Use only the special tools, test equipment and spare parts specified by the manufacturer.

– Only competent persons who have been trained in how to work with Linde lithium-ion technology may work on the batteries.

– Before carrying out any work on the battery, put on personal protective equipment and disconnect the battery.

– Never short-circuit the battery connectors.

– Do not connect the battery with the polarity reversed.

– Do not subject the battery to excessive mechanical loads.

– Water can be used to cool down the incipient fire.

DANGER Risk of explosion!

– Never heat the battery to over 80 °C or expose it to naked flames.

DANGER Risk of injury!

The battery may be damaged or deformed in the event of an accident (impact, fall, collision). A strange smell, an abnormal rise in temperature to >80°C, a change in shape or any other anomaly may occur.

– Establish a safety zone of five metres around the battery.

– Ensure sufficient ventilation.

– If necessary, contact the emergency services and inform them that there has been an accident involving a lithium-ion battery.

Other applicable standards and directives DIN VDE 0100-410 voltage range I (for batteries in battery groups 1 to 4) DIN VDE 0105-100:2009-10 NOTE

Comply with the national laws and regulations of the country in which the battery is used!

Personnel qualifications According to the general principles for safe operation, all persons involved in work with or in the vicinity of electrical systems must be given instruction on the following subjects: • Safety requirements

NOTE

• Safety regulations

Before extinguishing fires, position yourself on the side of the fire from which the wind is blowing.

This will prevent inhalation of toxic fumes.

• Operating instructions Requirements for qualified personnel: • Personnel must be approved according to the current requirements of IEC 60449 or DIN VDE 0100-410 • Observe instructions, regulations and requirements • Wear suitable clothing for the work place

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Product information

00 Safety information

• Wear personal protective equipment when opening the battery or the technology compartment • The person responsible for the work must ensure compliance with these requirements before starting work and during the work.

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00

Product information

Safety information Intended use The battery must be used only in accordance with the following documents: • The original operating instructions for the industrial truck Use the battery only when it is in good working order: • The battery must not be damaged and must not indicate any errors • The cables to the battery charger must not be damaged • The cables to the industrial truck must not be damaged.

The battery must only be used in a suitable industrial truck. The nominal voltage of the battery must correspond to the operating voltage of the industrial truck (see "Technical data").

Charge the battery using only the battery charger for lithium-ion batteries approved by the manufacturer.

NOTE

If the charging state is less than 10%, charge the battery as soon as possible. Leaving the cells discharged for several days negatively affects the service life of the battery.

NOTE

When taking the battery out of operation for a prolonged period (e.g. for company holidays), always ensure the battery is charged (50% 100%).

Dangerous misuse DANGER

DANGER

Improper handling can lead to an explosion or cause a fire!

The penetration of water can cause short circuit and fire!

– Never use the battery in areas where there is a risk of fire or a risk of explosion.

– Prevent liquids from penetrating the battery.

– Never heat the battery to over 80°C or expose it to an open flame.

DANGER A short circuit can destroy the battery and start a fire!

– Do not short circuit the battery.

DANGER

– Keep the pin contacts away from metallic objects.

Improper handling or causing intentional damage to the battery can result in serious injuries!

– Use the battery only in accordance with the manufacturer's instructions.

– Do not improperly dismantle the battery.

– Do not disassemble, bridge or bypass the safety systems.

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Product information

00 Safety information

Procedure in the event of a battery-related accident WARNING

NOTE

When used properly the battery will not catch fire and there is no possibility of contact with toxic substances. When the battery is handled correctly there is no possibility of an electric shock.

Escaping gases can lead to breathing difficulties!

– Immediately ventilate the area or go out into the fresh air; in more serious cases, call a doctor immediately.

– Do not move the battery.

WARNING

Procedure in the event of a fire

Leaking chemicals can irritate the skin and the eyes!

DANGER Risk of poisoning by inhalation of vapours.

If the battery catches fire, toxic vapours will be released.

– Immediately wash affected areas of skin thoroughly with soap and water.

– Thoroughly irrigate eyes with clean water.

– Seek medical assistance immediately.

– Position yourself on the side of the fire from which the wind is blowing.

– Immediately clear the area around the battery, retreating to a minimum distance of 5 m.

– Use respiratory protection.

– Call the fire brigade.

– Water can be used to cool down the incipient fire.

NOTE

The battery must be moved to a safe area (5 m away from buildings) by specially trained personnel.

Procedure in the event of electric shock

DANGER

DANGER

Risk of fire due to the battery overheating!

The battery can become very hot when in use. Temperatures in excess of 80°C must always be avoided.

Providing incorrect first aid to the injured person can create additional risks!

If the battery reports a temperature that is too high, cool the battery from the outside. Water can be used to cool down an incipient fire.

– Do not touch the injured person before ensuring the power supply has been disconnected.

– Make sure that the temperature limits are not exceeded.

– Move exposed live cables away from the injured person using non-conductive objects.

– Cool the battery to below the temperature limits.

– Ensure the injured person is breathing and has a heartbeat.

– Cool the outside of the battery tray with water.

– Treat burns injuries appropriately.

– Consult a doctor immediately.

Lithium-ion battery: First-aid measures Measures required if gases or liquids escape: Escaping gases can lead to breathing difficulties.

– Immediately ventilate the area or go out into the fresh air; in more serious cases, call a doctor immediately.

Skin irritation can occur in the event of contact with the skin.

– Thoroughly wash the skin with soap and water.

Eye irritation can occur in the event of contact with the eyes.

– Immediately rinse eyes thoroughly with water for 15 minutes, then consult a doctor.

Measures required in the event of electric shock: – 1. Ensure that the system is disconnected from the power supply. Do not touch the injured person until this has been done!

– 2. Move exposed live cables away from the injured person using non-conductive objects.

– Call an ambulance.

If the person is unconscious: – Begin first-aid measures.

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00

Product information

Transport and storage Battery transport with crane

2

DANGER If the load is dropped, the consequences could potentially be fatal!

– Never walk or stand underneath suspended loads.

– Ensure there is sufficient distance between the truck and any obstacles so that the truck is not damaged when the crane is used.

1

To avoid short circuits, batteries with open terminals or connectors should be covered with a rubber mat.

– Attach battery (1) to suitable lifting gear (2).

6210_003-012

Observe the operating instructions for the lifting gear.

The lifting gear should be vertical when lifting, so that no lateral pressure is applied to the tray.

– Lift the battery from the roller channel. Ensure that there is sufficient distance from the battery door.

– Set the battery down carefully.

– Do not place or allow slack lifting gear to fall on the battery cells.

Transport directives CAUTION For transportation purposes, lithium-ion batteries are classified as class 9 dangerous goods (UN 3480 for individual batteries and UN 3171 for a batterypowered truck/device) and assigned to packing group II.

The batteries are carefully packed to minimise the likelihood of any damage during transport.

However, the batteries must still be thoroughly inspected for damage after any transportation.

The load must be carefully secured against falling, tipping or slipping during transportation.

Only suitable means of transport may be used.

Only competent persons may perform transportation and the necessary preparations.

Lithium-ion batteries are always hazardous materials and are subject to the current version

00-6

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Product information

00 Transport and storage

of the following hazardous materials regulations and exceptions.

For further information on the transport guidelines, see the document entitled "STILL lithiumion technology properties, storage, transportation and processes".

NOTE

Please contact the person in your organisation trained for this purpose.

Storage For information about the storage of lithium-ion batteries, see the document entitled "STILL lithium-ion technology properties, storage, transportation and processes".

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00

Product information

Description of lithium-ion battery Structural principle of the battery cell A lithium-ion cell consists primarily of the following four components:

The electrolyte is an anhydrous solution. The electrolyte used is assigned to hazardous substances class "Carc. Cat. 3, C, R10-34-40-43".

• Anode • Cathode

The separator physically separates the anode from the cathode to prevent a short circuit. The separator is permeable for ions to convert the stored chemical energy into electrical energy.

• Separator • Electrolyte The anode is mainly a compound of lithiumnickel-manganese-cobalt oxide.

Typical separators used in lithium-ion cells are: • Polymers foils

The cathode consists mainly of graphite (carbon).

In addition, binders such as polyvinylide difluoride and thin metal carrier foils such as aluminium foil and copper foil are used.

• Ceramic-coated membranes • Microporous ceramics

Chemical equation NOTE

Oxidation: LixC6 → Li1-xC6 + x Li+ + x eReduction: Li1-xNiaMnbCocO2 + x Li+ + x e- → LiNiaMnbCocO2

The same electrode acts either as anode or cathode depending on the charging or discharging procedure. I.e., the anode can function as the positive or negative electrode, as can the cathode.

Charging/discharging - operating principle 1

2

Graphit

LiCoO2

Graphit

LiCoO2

Li +

Li + Li +

Li + Li +

A

Li +

B

A

B 386_000-011

1 2

Charging Discharging

A B

Cathode Anode

NOTE

The same electrode acts either as anode or cathode depending on the charging or discharging procedure. The anode can function as the positive and negative electrode, as can the cathode.

Charging process During charging, lithium ions flow from the positive electrode (cathode) through the separator.

Lithium graphite is produced at the negative electrode (anode); cobalt manganese and nickel

00-8

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Product information

00 Description of lithium-ion battery

oxide are created at the positive electrode (cathode) → chemical energy.

Discharging process During discharging, lithium ions flow from the negative electrode (cathode) through the separator.

Graphite is produced at the negative electrode (cathode); lithium metal oxide (CO, Mn, Ni) is created at the positive electrode (anode) → electrical energy.

Advantages of lithium-ion technology Advantages: • Very high energy density • High efficiency of up to 95% (ratio of discharge current quantity/charge current quantity) • Same capacity with less volume and less mass • Discharge to 5% residual capacity possible • Very long service life (2 or 3 times as long as conventional batteries) • High number of charge cycles (at least 2500 cycles at 80% SoH, "second battery life" possible) • "Balancing": load balancing of cells connected in series for maximum capacity utilisation • No negative effects caused by partial charging, no memory effects • Short charging time • Fast intermediate charging • Very low energy loss when charging compared to lead-acid batteries • Energy costs can be lowered by up to 40% • Low self-discharge rate • Eliminates need for battery replacement or replacement batteries • No maintenance, e.g. topping up water • Reduced energy and handling costs • No leaking battery gas or battery acid • Environmentally friendly (do not contain any toxic substances such as cadmium, lead or mercury) → Raw materials easy to recycle

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00

Product information

Description of lithium-ion battery Structural principle of the battery module

1 2 3 4 5 6 7

Battery cells (13 pieces) Battery modules Power supply Battery module controller (CSC) Balancing controller Balancing battery cells Voltage of the battery module

8 9 10 11 12 13 14

Microcontroller Voltage of the battery cells Temperature CAN bus Monitoring signal Battery master controller (BMC) Temperature sensors

The battery module consists of a sheet steel enclosure and contains several components.

Within the battery module, the battery cells are connected to each other by cell connectors.

There are 13 battery cells arranged in series, thereby achieving a nominal voltage of 48 V. The positive connection and negative connection are designed as plug contacts on the battery module. There is a 200 A fuse in the negative side of the circuit. For vertically mounted battery modules, the positive connection is at the top and the negative connection is at the bottom of the battery module.

At the top of the battery module there are two plug connectors for connecting the battery module to the battery CAN bus and supplying the battery module with voltage. The battery module is also connected to a monitoring signal (Fault Line Signal) via the plug connector. It is then connected to the next battery module in each case via the two plug connectors. A terminating resistor (120 Ω) for the CAN bus is fitted on the last battery module.

The battery module is monitored by the battery module controller (CSC). The CSC monitors each 00-10

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Product information

00 Description of lithium-ion battery

individual cell voltage and the overall voltage of the battery module. Parallel to each battery cell there is a balancing unit. This is activated by the CSC during the charging process in order to maintain equality of the cell voltages.

Main components

9

1

10

8

2

3 7 6

5 1 2 3 4 5

Cell connector 200 A module fuse Negative terminal Cell voltage measurement Cell

4 6 7 8 9 10

50988012057 EN - 12/2017

386_000-003

Module housing Battery module controller (CSC) Positive terminal LED display Module connector

00-11

00

Product information

Description of lithium-ion battery Exploded view

1

2 3 8

4 7

6

5 386_000-004

1 2 3 4

00-12

Module cover Cell connector Cell cover Cells (13 units)

5 6 7 8

Module housing Housing insulation End plate Battery module controller (CSC)

50988012057 EN - 12/2017

Product information

00 Description of lithium-ion battery

Temperature sensors

1 2

NTC 1 NTC 2

3 4

NTC 3 NTC 4

1

LED display

Battery module LED display

Time Red/green LED

1s

1s

1s

1s

1s

1s

1s

Red

1s

1s

1s

1s

1s

Green

OFF/quiescent state

(off)

(off)

Battery reset Module not detected by master Error Flash procedure active Normal operation - no faults

1x

1x

3x

3x

.

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00

Product information

Description of lithium-ion battery

Balancing Balancing refers to equalisation across a battery module. This ensures an even voltage level between the cells. It is a continuous internal process.

The voltage value is displayed in the diagnostics.

Passive balancing Resistors connected in parallel that discharge the cells in a targeted manner during the charging process.

Advantage • Low-cost variant • Low component requirements • Small footprint Disadvantage • Energy is converted into heat 1 2 3

Rext1 I-balance Battery cell

Battery display

1

Charging state LEDs The battery display is switched on when the battery is communicating with the truck, the battery charger or the diagnostic device. The charging state LEDs (3) indicate the charging state of the battery. All charging state LEDs (3) light up green in sequence when the battery is charging.

Display

00-14

Charging state Comment (%) First charging state LED flashes red: 0-2 the truck can no longer be moved.

First charging state LED lights up red: drive to > 2 - 10 the charging station immediately

3

2 386_609-007

1 2 3

Service LED Temperature LED Charging state LED

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Product information

00 Description of lithium-ion battery

Display

Charging state Comment (%) > 10 - 20 > 20 - 30 > 30 - 40 > 40 - 50 > 50 - 60 > 60 - 70 > 70 - 80 > 80 - 90 > 90 - 100

.

Service LED If the service LED (1) lights up, battery function is significantly restricted or operation is not possible. The service LED goes out as soon as the fault is no longer present.

Temperature LED The temperature LED (2) indicates an increased battery temperature. Battery power is reduced or switched off. The temperature LED remains active for the run-on time or until the normal temperature range is reached again.

Temperature Slightly Flashing yellow increased (> 60°C) Increased (> Solid yellow 65°C) Significantly Flashing red increased (> 70°C) Greatly increased Solid red (> 75°C) LED status

Result Power reduction Shut-off Shut-off Shut-off

.

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00

Product information

Description of lithium-ion battery Battery management system (BMS)

1. Technology compartment BMC Battery controller BCM Brake chopper module CVS Current/voltage sensor CS Shock sensor and battery display SSV Control voltage supply

2. Battery tray CSC Battery module controllers

The battery management system (BMS) contains various controllers that communicate with one another via CAN bus systems. The battery controller (BMC) is the main processor in this system. Each battery module has its own battery module controller (CSC). The BMS is powered by the battery itself.

• Operating the battery module via the internal CAN bus

Tasks of the battery controller (BMC)

Internal CAN bus (CAN 2.0, 500 kB/s)

3. Interfaces X34 Communication plug X33 Diagnostic connector

• Controlling and monitoring all battery functions • Communicating with the truck • Collecting all battery data and formatting it for the truck • Recording all operating and diagnostic data relating to the battery • Processing the data supplied by the truck

• Permanent Balancing The BMS contains independent CAN bus systems for data transfer between the controllers and for communication with the truck.

• A CAN star circuit connects the controllers in the technology compartment • A CAN series circuit connects the battery module controllers in the battery tray External CAN bus (CANopen, 500 kB/s) • Communication with the truck

Task of the battery module controllers (CSC): • Monitoring the individual battery cells in a battery module • Sending data to the BMC and retrieving data from the BMC

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Service

01

a

Maintenance and repair Service plan Every 3 months

NOTE

The lithium-ion battery requires no special maintenance work. However, there are some tasks outside the service plan that must be taken into account.

At delivery and after 40 days in storage • Fully charge the battery

• Fully charge the battery Every 1000 hours / every year • Visually inspect all components • Visually inspect the labelling points (marking and adhesive label) • Visually inspect the tray lid and battery tray for damage • Check the strength of the power connection pins

Regular tasks • Clean the battery • Check the battery connections and battery cables • Visually inspect the covers

• Check the strength of the battery male connector and cables • Check the strength of the diagnostic connector

• Charge the battery

Cleaning the battery – Cleaning electrical system parts with water is forbidden!

DANGER Dangerous electrical voltage!

– Do not wear jewellery or metal objects when working directly on batteries.

– Do not spray electrical components or their covers directly with water.

CAUTION

CAUTION

Risk of fire!

Risk of short circuit!

The battery is located in an enclosed and splash-proof battery tray. Excessive water pressure or water and steam that are too hot can damage components.

Water ingress can cause a short circuit and damage the battery.

– Always switch off the electrical system before cleaning.

– Make sure that all openings of the battery that can be closed are closed correctly.

– Only use high-pressure cleaners with a maximum output power of 50 bar and at a maximum temperature of 85°C. – When using high-pressure cleaners, make sure there is a distance of at least 20 cm between the nozzle and the object being cleaned.

– Do not aim the cleaning jet directly at adhesive labels or decal information.

Flammable fluids can be ignited by hot components.

– Do not use flammable fluids for cleaning.

– Follow the instructions of the cleaning material manufacturer.

– Never clean brake resistors with cleaning materials, only clean them of dust without applying liquids.

Lithium-ion batteries do not require any special maintenance work. Regular cleaning according to usage is recommended.

– Switch off the industrial truck and secure it against being switched back on.

– Clear access to the battery in the industrial truck.

– Check the condition of the connections.

– When cleaning, wear protection goggles and a dust mask if required.

– Blow out dust and dirt with low-pressure compressed air or a vacuum cleaner.

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01

Service

Operating materials Tools, insulated up to 1000 V DANGER Risk to life due to short circuit.

– Do not use tools with damaged or worn insulation.

– Use only genuine bits with a maximum length of 25 mm.

– Do not use a tool if the bit locking system is loose.

Bits could fall out of the support mounting and cause a short circuit between live components.

Designation

Part number

Service case with tools insulated up to 1000 V, fully equipped

0009416021

1

Torque wrench, insulated, reversible, 3/8", 2.5–25 Nm

0009419915

2

Reversible ratchet, insulated, 3/8", 32-tooth

0009419916

3

0009419917

4

Extender for socket, insulated, short, 3/8", 125 mm Extender for socket, insulated, long, 3/8", 250 mm

5

Socket, insulated, 3/8", 7 mm

0009419919

6

Socket, insulated, 3/8", 8 mm

0009419920

7

Socket, insulated, 3/8", 10 mm

0009419921

8

Socket, insulated, 3/8", 13 mm

0009419922

Socket, insulated, 3/8", 15 mm

9 10 Socket, insulated, 3/8", 16 mm 11 Socket, insulated, 3/8", 17 mm 12 Hexagon hole screwdriver, insulated, 2.5 mm

0009419923

13 Hexagon hole Allen key, insulated, 3 mm 14 Hexagon hole Allen key, insulated, 4 mm 15 Hexagon hole Allen key, insulated, 5 mm 16 Hexagon hole Allen key, insulated, 6 mm

0009419927

17 Hexagon hole Allen key, insulated, 8 mm 18 Open-ended spanner, insulated, 10 mm

0009419931

19 Open-ended spanner, insulated, 17 mm 20 Long-nosed pliers, insulated, 230 mm

0009419933

21 Tweezers, insulated, bent, 11.5 mm 22 Extender for bit, insulated, short, 3/8", 125 mm 23 Extender for bit, insulated, long, 3/8", 250 mm

0009419935

24 Bit set for hexagon hole and Torx, 24-piece 25 Insulated grommet with clamping cap, 17.5 mm, x4

0009419938

26 Insulated grommet with clamping cap, 26 mm, x4

0009419940

.

01-2

50988012057 EN - 12/2017

0009419918

0009419924 0009419925 0009419926 0009419928 0009419929 0009419930 0009419932 0009419934 0009419936 0009419937 0009419939

Service

01 Operating materials

Personal protection equipment (PSA) Designation Part number Electricians' protective gloves in line with EN 60903:2003 or CEI 60903:2003 (gloves made from natural rubber) A half-yearly visual inspection is specified for class 00 Size 08 7654200078 Size 09 7654200079 Size 10 7654200080 Protective visor in accordance with EN 50365 Lithium-ion workwear. Protection against sparks and welding spatter

Size 11 7654200081 Acquire independently See STILL catalogue

.

Special tool for lithium-ion technology Designation

Part number

STILL multimeter, including measurement leads

0009418737 Acquire independently

2-pole voltage detector, e.g. DUSPOL-analog Adhesive labels, service seals Insulating mat 80 x 120 cm Protection against contact for positive rail in the technology compartment, insulated SSV-Dongle Module removal tool Kit module packaging

50984391300 Acquire independently Number not yet known 0009750855 Number not yet known Number not yet known

Balancing-Tool

Number not yet known

.

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01-3

01

Service

Operating materials Attaching/removing the lifting tool Attaching – Insert the lifting tool (1) with the detent cams under the socket head screws (4) and into the bores (3) of the module.

– Slide the lifting tool so that the rear latches engage with the slots (2).

NOTE

The detent cams underneath the socket head screws (4) each have a recess. When they are moved into the bores, the detent cams engage under the module plate.

– Push the locking plate (6)outwards into the recess of the surrounding crosspiece.

NOTE

The locking plate prevents the movement of the lifting tool, therefore preventing the latches and indexing bolt from slipping out of the module.

– Insert the Perspex plate with the eye bolt (7) into the lifting tool.

The locking plates are now fixed in place and the lifting tool is firmly attached to the module.

– Attach the hoist to the module and to the bracket (8) of the lifting tool.

Removing – Remove the Perspex plate with the eye bolt (7) from the lifting tool.

– Push the locking plate (6) inwards from the recess of the all-round lip.

– Push the lifting tool away from the rear engagement slots (2) until the detent cams under the socket head screws (4) hook onto the bores (3) and the rear latches are exposed.

– Remove the lifting tool (1) from the module.

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Service

01

Battery charge Battery discharge Cell voltage Status of the battery The charging state of the battery is 100% The last LED lights up red: The charging state of the battery is >2% to 10% The last LED flashes red: The charging state of the battery is <2% 3.0 V It is no longer possible to drive the truck.

The battery display is OFF. The service LED lights up red The control voltage supply unit (SSV) 2.97 to 2.28 V has switched off the BMC. It is still possible to establish CAN bus communication between the battery and the charger

The battery or cells are deeply discharged

Below 1.5 V Battery cell damage The battery management system (BMS) is powered by the battery itself. The BMS cannot be switched off. For this reason, the battery discharges slowly but continuously even while it is in storage.

The discharge limit is 3.0 V, which corresponds to a battery capacity of < 2%. Discharging the battery below the discharge limit is known as deep discharging.

The control voltage supply unit (SSV) switches off the lithium-ion battery at 2.97 V. CAN bus communication between the battery and the charger can still be established until the level reaches 2.28 V. The customer can charge the battery using the charger. It takes approximately

Deep discharge begins from 3.0 V Battery discharge takes approximately 8 to 10 days It is still possible to charge the battery using the charger

Battery discharge takes approximately 87 days The battery must be put back into service by a service technician qualified to work with high-voltage equipment.

Battery discharge takes approximately 10 days The battery can only be put back into service by the manufacturer.

The battery is broken. It may be possible to replace faulty cells.

The battery display and the LEDs are OFF. 2.28 V to 2.0 V It is not possible to establish CAN bus communication with the charger

2.0 V to 1.5 V

Connect the charger immediately

eight to ten days for the battery to self-discharge from 3 V to 2.28 V. After a further 87 days, the battery will have discharged to approximately 2.0 V. Deeply discharged lithium-ion batteries may only be charged by service technicians who are qualified to work with high-voltage equipment. The technology compartment of the battery must be opened for charging.

After another ten days, the cell voltage falls below 2.0 V. The battery can now only be put back into service by the battery manufacturer. Irreparable cell damage occurs when the cell voltage falls to 1.5 V.

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01-5

01

Service

Battery charge Course of action for a deeply discharged battery Battery charging performed by the customer Truck status: • The truck is switched off and cannot be switched on.

• The battery display is off.

• The service LED on the battery lights up red.

• The control voltage supply unit (SSV) of the battery is switched off.

• Communication with the battery via diagnostic connector X33 is possible.

• The battery is able to establish communication with the charger.

– Park the truck securely.

– Disconnect the battery male connector.

– Connect the charger to the battery.

The charging process starts automatically. The No control voltage warning message appears in the display on the charger.

NOTE

The battery male connector must not be disconnected before the charger has completed the charging process or before the STOP button on the charger has been pressed.

– If the charging process does not start automatically, pull out the battery male connector and wait 5 minutes.

Usually, the battery master controller (BMC) changes back to the quiescent state during this time. The quiescent state is not visible.

– Connect the charger again.

Battery charging performed by an authorised service technician Requirements: • The truck is switched off and cannot be switched on.

• The battery display is off.

• The service LED on the battery does not light up.

• Communication with the battery via the diagnostic connector X33 is not possible.

• The battery is not able to establish communication with the charger.

– Park the truck securely.

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Service

01 Battery charge

– Disconnect the battery male connector.

– Check for control voltage at the battery male connector.

If there is a control voltage at the battery male connector, the battery has a different fault. The battery is not deeply discharged.

If there is no control voltage at the battery male connector, you may continue with the remaining work steps: – Carry out an insulation measurement.

– Check the battery voltage at the battery male connector.

If there is a battery voltage at the battery male connector, this means that the contactors are jammed. The battery has a different fault.

If there is no battery voltage at the battery male connector, you may continue with the remaining work steps: DANGER Dangerous electrical voltage!

Touching live components can lead to an electric shock, which can have thermal or paralysing effects.

– Wear personal protective equipment.

– Use insulated tools.

– Open the maintenance cover of the technology compartment.

– Remove the fuse F2 from the fuse holder (1).

– In the technology compartment, measure the battery voltage between the main fuse F1 and battery negative.

UNominal

UMeasured

48 V

26 to 39 V

80 V

48 to 72 V

If the value measured is UNominal, the battery has a different fault. The battery is not deeply discharged.

If the value measured is UMeasured, you may continue with the remaining work steps:

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01-7

01

Service

Battery charge – Depending on the battery group, it may be necessary to remove components in order to make the plug X52 on the control voltage supply unit (SSV) accessible.

– Disconnect the plug X52 from the control voltage supply unit (SSV).

X52 – Attach the SSV-Dongle(4) to the plug X52 on the cable harness.

The SSV-Dongle bridges Pin 2 and Pin 4.

4

– Insert the fuse F2 back into the fuse holder (1).

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Service

01 Battery charge

– Check the function of the battery master controller (BMC). The blue LEDs and the white LEDs must be flashing.

The battery master controller (BMC) is active again. The battery display is on.

– Connect the battery to the charger. The charging process starts automatically.

NOTE

In some cases, the charging process stops again after a few seconds. In this case, the battery male connector must be disconnected from the charger.

• Wait until all LEDs on the BMC have gone out.

The BMC is in the quiescent state.

• Now connect the charger again. This process can be repeated up to five times.

If the charging process does not start automatically, then there is a serious fault. The battery can neither be charged on site nor repaired. Read out any error messages that appear on the charger.

NOTE

The battery male connector must not be removed during the charging process. The charging process may only be terminated prematurely via the STOP button on the charger.

Charge the battery until at least three green bars light up in the battery display. This is equivalent to a charging state (also known as state of charge, or SOC) of > 20%.

– End the charging process. Press the STOP button on the charger.

– Disconnect the battery from the charger.

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01

Service

Battery charge – Remove the fuse F2 from the fuse holder (1).

– Disconnect the SSV-Dongle (4) from the plug X52 on the cable harness.

– Connect the plug X52 to the control voltage supply unit (SSV).

4

– Insert the fuse F2 back into the fuse holder (1).

Removing the fuse F2 interrupts the power supply to the components. Even after the fuse F2 has been re-inserted, the battery master controller remains in the quiescent state. A reset must be carried out to wake up the battery master controller.

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Service

01 Battery charge

– Press the reset button (5) on the control voltage supply unit (SSV).

The batter master controller is active again. The battery display is on.

5

– Check the function of the battery master controller. The blue LEDs and the white LEDs must be flashing.

– Reinstall all components that needed to be removed based on the battery group back into the technology compartment.

– Put the maintenance cover back in place to close off the technology compartment.

The personal protective equipment can now be removed.

– Connect the charger to the battery.

The charging process starts automatically.

NOTE

The battery male connector must not be removed during the charging process. The charging process may only be terminated prematurely via the STOP button on the charger.

– If the charging process does not start automatically, pull out the battery male connector and wait 5 minutes.

Usually, the battery master controller (BMC) changes back to the quiescent state during this time.

– Connect the charger again.

If the charging process does not start again, there is a serious fault. The battery can neither be charged on site nor repaired.

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01-11

01

Service

Function checking Checking that the battery male connector is de-energised Measuring equipment • 2-pole voltage detector

Measuring at the battery male connector – If the battery is still in the truck, disconnect the battery male connector.

Battery voltage is present at the pilot contact (Batt+) even after the battery male connector has been disconnected.

– Disconnect the plug X34 on the battery.

– Measure from the pilot contact (Batt+) to the negative terminal (-) of the battery male connector.

Test result: 0 V; no electrical voltage is present.

– Measure from the positive terminal (+) to the negative terminal (-) of the battery male connector.

Test result: 0 V; no electrical voltage is present.

If there is a battery voltage at the battery male connector, this means that the contactors are jammed.

CAUTION Dangerous electrical voltage!

If battery voltage is present at the plug, the contactors are not open. The contactors are jammed.

– All subsequent work on the battery must be performed by a service technician qualified to work with high-voltage equipment.

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Service

01 Function checking

Insulation testing the lithium-ion battery Measuring equipment • STILL MetraHit ISO multimeter

Test values Component Battery

Recommended test voltage

Measurements Batt+ Batt-

500 VDC

Battery tray

Nominal voltage UBatt 24 volts 48 volts

Test values 2.8 GΩ to 1 MΩ

80 volts

.

Performing battery measurements – If the battery is still in the truck, disconnect the battery male connector.

– Set the measuring device to the recommended test voltage.

– Measure from the positive terminal (L+) of the battery to an electrically conductive point on the battery tray.

– Measure from the negative terminal (L-) of the battery to an electrically conductive point on the battery tray.

NOTE

The bare screws on the cover of the technology compartment are suitable conductive points.

DANGER The insulation resistance measured is below 1 MΩ.

The battery is unsafe and must not be used again.

Switch off the battery. Contact the authorised service centre immediately.

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01

Service

Function checking

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Battery group 2.1

21

a

Design BG 2.1 Technical data for battery group 2.1

Parameter Cell connection Nominal energy

Unit Serial/parallel

Value 13 / 4

kWh

13.1

Nominal capacity

Ah

268

Nominal voltage

V

48.75

Final charged voltage

V

53.6

Final discharged voltage

V

35.1

Discharge current (maximum)

A

400

Discharge power (maximum)

kW

18

Dimensions and weights

Unit mm

Value

mm

529

mm kg

350

Length Width Height Weight

1030

850

Safety Protection class Fire protection rating

IP6K9K External housing/13S cell module

A2/B2

.

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21

Battery group 2.1

Design BG 2.1 Diagnostic set-up The diagnostic connector can be used to enter and read out battery data with a laptop and the diagnostic program.

– Unscrew the lid (2) in an anti-clockwise direction.

– Connect a laptop to the diagnostic plug X33 (1).

NOTE

After completing diagnostics, screw the lid (2) back onto the diagnostic connector (1). This prevents the ingress of moisture.

NOTE

The diagnostics can also be accessed via the diagnostic connector of the truck while the battery is still installed. If the battery is in the truck, the battery male connector must be disconnected from the truck in order to carry out diagnostics.

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21 Design BG 2.1

Design - Battery group 2.1

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21

Battery group 2.1

Design BG 2.1 1 2 3 4 5

Metal rail Tray cover Module cover Module holder with positive/negative power connector Front weight package

6 7 8 9 10

Technology compartment Maintenance cover Brake resistor Connections for power, communication and diagnostics Tray

Technology compartment - Battery group 2.1

A B C D E F G

21-4

Power cables Auto plug-in fuse Battery master controller (BMC) Control voltage supply unit (SSV) Voltage transformer (DC/DC) Pressure compensation element Brake chopper module (BCM)

H I J K L M

Main fuse Contactor assembly Diagnostic plug X33 Communication plug X34 Positive power connection (+) Negative power connection (-)

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Battery group 2.1

21

De-energised state BG 2.1 Measuring the insulation resistance The insulation measurement steps described below must be carried out on the battery before and after any repair work.

DANGER Dangerous electrical voltage!

Touching live components can lead to an electric shock, which can have thermal or paralysing effects.

– Wear personal protective equipment.

– Use insulated tools.

Special tools • Personal protective equipment • Insulation measuring device

Measuring the insulation resistance – Disconnect the battery male connector from the industrial truck.

– Set the insulation tester to U = 500 V DC. During the test, the BMS must be connected and the contactors must be open (perform the insulation testing anyway if the contactors are stuck).

– Connect the insulation tester to an unpainted socket head screw (1) on the maintenance cover (2), and to the negative terminal of the truck plug (3).

– Measure the insulation resistance.

The insulation resistance (Riso) must be > 1 MΩ.

– Connect the insulation tester to an unpainted socket head screw (1) on the maintenance cover (2), and to the positive terminal of the truck plug (3).

– Measure the insulation resistance.

The insulation resistance (Riso) must be > 1 MΩ.

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21

Battery group 2.1

De-energised state BG 2.1 De-energising the technology compartment DANGER Dangerous electrical voltage!

Touching live components can lead to an electric shock, which can have thermal or paralysing effects.

– Wear personal protective equipment.

– Use insulated tools.

Special tools • Personal protective equipment • Hexagon socket wrench AF 4 • Fuse puller • Torque wrench AF 15 • Two-pole voltage detector in line with DIN VDE 0682-401:2011-02 (DIN EN 61243-3) • Insulating mat in accordance with DIN VDE 0682-511 [EN/IEC 61112], 1000 V • Safety device (part number: 0009418815)

Removing the front module cover – Measure the insulation resistance, see the section entitled "Measuring the insulation resistance".

– Remove the power cable, see the section entitled "Removing/installing the power cable".

– Remove the tray cover; see the section entitled "Removing/attaching the tray cover".

– Mask the lift hole on the front module cover (1).

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21 De-energised state BG 2.1

– Unscrew the M10x20 screws (1).

– Remove the adhesive label from the lift hole.

WARNING Risk caused by lifting heavy loads!

Manual lifting and handling is permitted only up to a maximum weight of 25 kg.

– Use a suitable hoist or transport vehicle for items above 25 kg.

– Remove the front module cover (2).

Weight: 10.5 kg

– Cover live parts in the battery tray (2) with an insulating mat (1).

Pulling out auto plug-in fuse F2 WARNING When pulling out a fuse that is connected to a live voltage, a small arc fault may occur.

– Remove the fuse using a fuse puller.

– Pull out the auto plug-in fuse F2 (1).

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Battery group 2.1

De-energised state BG 2.1 Opening the technology compartment – Unscrew the M6x10 screws (1).

WARNING Risk caused by lifting heavy loads!

Manual lifting and handling is permitted only up to a maximum weight of 25 kg.

– Use a suitable hoist or transport vehicle for items above 25 kg.

– Remove the maintenance cover (2).

Weight: 9 kg

Removing the main fuse DANGER Dangerous electrical voltage!

Voltage is still present at the positive fuse input.

Touching live components can lead to an electric shock, which can have thermal or paralysing effects.

– Wear personal protective equipment.

– Use insulated tools.

– Pull out the protective caps (if present) (1).

– Unscrew the M10x20 ratchet screws (2) – Remove the main fuse (3).

DANGER Dangerous electrical voltage!

Voltage is still present at the positive fuse input.

Prevent accidental touching or short-circuiting of the input side of the main fuse, which is still live.

– When making repairs in the technical compartment of the battery, the insulated safety device must be attached after removing the main fuse.

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21 De-energised state BG 2.1

– Cover the conductor rail (1) with the safety device (2).

Checking that the technology compartment is de-energised DANGER Dangerous electrical voltage!

Voltage is still present at the positive fuse input.

Touching live components can lead to an electric shock, which can have thermal or paralysing effects.

– Wear personal protective equipment.

– Use insulated tools.

– Touch the two-pole voltage detector to the CVS negative (3) and the positive fuse input (1).

Test result: electrical voltage present.

– Test the two-pole voltage detector on the CVS negative (3) and the positive fuse output (2).

Test result: no electrical voltage present.

It is now safe to replace the components in the technology compartment.

Restoring operating status DANGER Dangerous electrical voltage!

Touching live components can lead to an electric shock, which can have thermal or paralysing effects.

– Wear personal protective equipment.

– Use insulated tools.

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21

Battery group 2.1

De-energised state BG 2.1 Special tools • Personal protective equipment • Hexagon socket wrench AF 4 • Insulation measuring device • Fuse puller • Torque wrench AF 15 • Two-pole voltage detector in line with DIN VDE 0682-401:2011-02 (DIN EN 61243-3)

Installing the main fuse – Remove the safety device (2) from the conductor rail (1).

– Fit the main fuse (3).

– Tighten the M10x20 ratchet screws (2).

Tightening torque: 18 Nm – Fit the protective caps (if available) (1).

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21 De-energised state BG 2.1

Closing the technology compartment WARNING Risk caused by lifting heavy loads!

Manual lifting and handling is permitted only up to a maximum weight of 25 kg.

– Use a suitable hoist or transport vehicle for items above 25 kg.

– Fit the maintenance cover (2).

Weight: 9 kg – Tighten the M6x10 screws (1) crosswise.

Tightening torque: 9 Nm

Inserting auto plug-in fuse F2 – Insert the auto plug-in fuse F2 (1).

NOTE If the SSV does not start automatically after reinserting the auto plug-in fuse F2, the SSV must be restarted manually. To do this, press the reset button on the SSV.

– Remove the insulating mat (1) from the battery tray (2).

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Battery group 2.1

De-energised state BG 2.1 Assembling the front module cover WARNING Risk caused by lifting heavy loads!

Manual lifting and handling is permitted only up to a maximum weight of 25 kg.

– Use a suitable hoist or transport vehicle for items above 25 kg.

Weight: 10.5 kg – Place the front module cover in position and mask the lift hole (1).

– Tighten the M10x20 screws (1).

Tightening torque: 15 Nm – Remove the adhesive label from the lift hole.

– Fit the tray cover; see the section entitled "Removing/fitting the tray cover".

– Fit the power cable; see the section entitled "Removing/installing the power cable".

– Measure the insulation resistance; see the section entitled "Measuring the insulation resistance".

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21

Components BG 2.1 Tray cover - Battery group 2.1 Unit mm

1030

Width Height

mm

529

mm

22

Screw joint

Piece

25

Length

Value

NOTE

The different types of cover design are not interchangeable.

1 2 3 4 5

Battery tray cover Bore for cover screw joint Recess for lifting eyes Duct for battery cable Cover seal

Removing/fitting the tray cover Special tools required: • Hexagon socket wrench AF 5

Removing – Measure the insulation resistance; see the section entitled "Measuring the insulation resistance".

– Remove the power cable and communication cable (3); see the section entitled "Removing/installing the power cable".

– Unscrew the M6x25 socket head screws (1) along with the washer.

– Repeat the procedure on the opposite side of the cover.

– Unscrew the M6x25 socket head screws (2).

– Repeat the procedure on the opposite side of the cover.

– Remove the cover rail (4).

– Lift off the tray cover (5).

– Take care not to damage the seal on the underside of the tray cover when lifting off the tray cover.

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Battery group 2.1

Components BG 2.1 Fitting Before fitting the tray cover, make sure: • The cover seal is in perfect condition and is positioned correctly in the seal groove on the underside of the tray cover • The cable inlet of the tray cover is located above the cable channel for the power and communication connections • The sealing face of the battery tray is clean and free of objects – Place the tray cover (5) in position.

– Make sure that the tray cover fits flush all around and that there is nothing lodged between the cover seal and the sealing face of the battery tray.

CAUTION Such objects may cause damage to the component or leakage around the tray cover.

If the mounting screws are tightened unevenly, this may distort the tray cover and cause the cover seal to leak.

– First, tighten all mounting screws by hand until the screw heads are seated.

– Always start by tightening the centre mounting screws and work outwards from there.

– Observe the different tightening torques.

– Screw in the M6x25 socket head screws (1) along with the washer.

– Repeat the procedure on the opposite side of the cover.

– Place the cover rail (4) in position.

– Screw in the M6x25 socket head screws (2).

– Repeat the procedure on the opposite side of the cover.

– Starting from the middle and working outwards, tighten the M6x25 socket head screws (2).

Tightening torque: 15 Nm – Starting from the middle and working outwards, tighten the M6x25 socket head screws (1).

Tightening torque: 9 Nm – Install the power cable and communication cable (3); see the section entitled "Removing/installing the power cable".

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21 Components BG 2.1

Battery display

1

Charging state LEDs The battery display is switched on when the battery is communicating with the truck, the battery charger or the diagnostic device. The charging state LEDs (3) indicate the charging state of the battery. All charging state LEDs (3) light up green in sequence when the battery is charging.

Display

Charging state Comment (%) First charging state LED flashes red: 0-2 the truck can no longer be moved.

First charging state LED lights up red: drive to > 2 - 10 the charging station immediately

3

2 386_609-007

1 2 3

Service LED Temperature LED Charging state LED

> 10 - 20 > 20 - 30 > 30 - 40 > 40 - 50 > 50 - 60 > 60 - 70 > 70 - 80 > 80 - 90 > 90 - 100 .

Service LED If the service LED (1) lights up, battery function is significantly restricted or operation is not possible. The service LED goes out as soon as the fault is no longer present.

Temperature LED The temperature LED (2) indicates an increased battery temperature. Battery power is reduced or switched off. The temperature LED remains active for the run-on time or until the normal temperature range is reached again.

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Battery group 2.1

Components BG 2.1 Temperature Slightly Flashing yellow increased (> 60°C) Increased (> Solid yellow 65°C) Significantly Flashing red increased (> 70°C) Greatly increased Solid red (> 75°C) LED status

Result Power reduction Shut-off Shut-off Shut-off

.

Removing/installing the battery display DANGER Dangerous electrical voltage!

Touching live components can lead to an electric shock, which can have thermal or paralysing effects.

– Wear personal protective equipment.

– Use insulated tools.

– De-energise the system.

Special tools required: • Hexagon socket wrench AF 3 • Personal protective equipment (PSA)

Removing – Ensure that the electrical system is de-energised; see the section entitled "De-energising the system".

– Disconnect the plugs X1 (1) and X2 (2) and the battery display/display electronics connecting cable (3).

– Unscrew the M4x10 socket head screws (5) along with the lock washer.

– Remove the display electronics (4).

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21 Components BG 2.1

– Unscrew the M4x6 socket head screws (3) along with the lock washer.

– Push the cradle (2) inwards along with the battery display (1) and remove these components.

– Disconnect the battery display/display electronics connecting cable (3) from the battery display (1).

– Leave an intact seal (2) on the battery display, do not remove it.

CAUTION Damage to the seal may occur.

The seal is attached to the battery display with its own adhesive strip. If the strip is pulled off, the seal may be damaged or destroyed, and the adhesive strip will lose its adhesive properties. Remove the seal only if it is damaged and a new seal is available for fitting.

– Leave an intact seal on the battery display.

– If the seal has been removed or damaged, replace it with a new seal.

Installing – Ensure that the electrical system is de-energised; see the section entitled "De-energising the system".

When reinstalling a battery display that has previously been removed, the following procedure must be followed:

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Battery group 2.1

Components BG 2.1 – Check that the battery display seal (2) is undamaged and can be reused. If not, then the seal must be replaced with a new seal.

When replacing a battery display that has previously been removed, the following procedure must be followed: – Pull off the protective film from the front of the new battery display (1).

– Pull off the protective film from the adhesive backing of the new seal (2).

– Position the new seal at an even circumference on the front face of the battery display and press the seal gently onto the glass casing.

– Connect the battery display/display electronics connecting cable (3) at the back of the battery display (1).

– Push the cradle (2) along with the battery display (1) and adhesively bonded seal into the recess.

– Screw on the M4x6 socket head screws (3) along with the lock washer.

Tightening torque: 2.5 Nm

– Align the display electronics (4) with the plug connections (1, 2) facing upwards on the tray wall.

– Route the battery display/display electronics connecting cable (3) upwards between the display electronics (4) and the tray wall.

– Connect the battery display/display electronics connecting cable to the plug connection (6).

– Screw on the M4x10 socket head screws (5) along with the lock washer.

Tightening torque: 2.5 Nm – Connect the plugs X1 (1) and X2 (2).

– Restore operating status; see the section entitled "Restoring operating status".

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21 Components BG 2.1

Schocksensor Der Schocksensor teilt sich die Platine mit dem Display und ist mechanisch starr an den Batterietrog angebunden.

G (m/s²)

Ein Schockereignis während der Ruhephase (Lagerung oder Transport) wird ebenfalls registriert und gespeichert.

Batterie im Flurförderzeug verbaut Schocklevel ≤ 10 G

10 G - 15 G

>15 G

Reaktion Ergebnis wird nicht im Fehlerspeicher der Batterie gespeichert.

Speichern des Ereignisses im Fehlerspeicher der Batterie, Senden von CANNachricht an das Fahrzeug, Reduzierung der Fahrgeschwindigkeit Starten der Batterie nicht möglich, Reset durch Servicetechniker nötig.

15 G 10 G t (min) 386_609-012

Transport der Batterie Schocklevel

>15 G

Reaktion Starten der Batterie nicht möglich, Reset durch Servicetechniker nötig.

Fehler kann über die Diagnose nicht zurückgesetzt werden.

.

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Battery group 2.1

Components BG 2.1 Pressure compensation element

1

The pressure compensation element is part of the safety concept of the battery system.

In normal operation, the membrane (3) equalises internal and external pressures.

The pressure cap (2) is connected to the housing (1) by a bayonet catch. If a critical over pressure (4) is reached, the pressure cap is pushed from the housing and the over pressure escapes.

4

2

3 386_691-024

1 2 3 4

Housing Pressure cap with bayonet catch Membrane Pressure "P"

Visual inspection DANGER Dangerous electrical voltage!

Touching live components can lead to an electric shock, which can have thermal or paralysing effects.

– Wear personal protective equipment.

– Measure the insulation resistance; see the section entitled "Measuring the insulation resistance".

– Unscrew the M6x10 screws (1) from the maintenance cover (2).

– Remove the maintenance cover (2).

– The pressure compensation element (3) is located behind the maintenance cover.

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21 Components BG 2.1

– Check that the pressure cap (1) is securely attached.

Pressure cap secure: If the pressure cap is firmly seated in the bayonet catch, no critical over pressure has occurred within the battery.

– Place the maintenance cover (2) into the recess in the tray.

– Tighten the M6x10 screws (1).

Tightening torque: 9 Nm Pressure cap loose: If the pressure cap is loose, a critical over pressure has occurred within the battery. A critical over pressure is caused by a serious defect within the battery. In the event of this happening, the battery must be tested by the manufacturer and repaired.

– Do not place the battery back in service; inform the battery manufacturer.

Removing/installing the module holder NOTE

The battery modules are located in a module holder and are not immediately accessible.

DANGER Dangerous electrical voltage!

Battery voltage is present between the POSITIVE power connectors and the NEGATIVE power connectors.

Touching live components can lead to an electric shock, which can have thermal or paralysing effects.

– Wear personal protective equipment.

– Use insulated tools.

– De-energise the system.

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Battery group 2.1

Components BG 2.1 Special tools required: • M8 lifting eyes • Suitable harnesses • Suitable hoist • Personal protective equipment • Insulating mats in accordance with DIN VDE 0682-511 [EN/IEC 61112], 1000 V • Spanner AF 10 • Spanner AF 12

Removing – Measure the insulation resistance; see the section entitled "Measuring the insulation resistance".

– Ensure that the system is de-energised; see the section entitled "De-energising the system".

– Cover live parts in the battery tray (2) with an insulating mat (1).

– Unscrew the M10x20 screws (3).

WARNING Risk caused by lifting heavy loads!

Manual lifting and handling is permitted only up to a maximum weight of 25 kg.

– Use a suitable hoist or transport vehicle for items above 25 kg.

– Put on personal protective equipment.

– Remove the rear module cover.

Weight: 8 kg – Remove the insulating mat from the battery tray.

– Loosen the M16 hexagon nuts (1) and remove them, along with the washers, from the guide rods.

– Screw the lifting eye into the internal thread (3) of the tie rod.

Thread size: M8 – Remove the weight package (2) from the battery tray by hooking it onto a suitable hoist using the lifting eye (3).

Weight: approx. 100 kg

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21 Components BG 2.1

– Loosen the M12x30 clamping bolts (1).

– Remove the protective cap and unscrew the M6x20 hexagon head screw (1) (negative power connector).

– Unscrew the M8 self-securing nut (2) from the decoupler threaded bolt.

– Unscrew the M10x25 mounting screws (1) from the module holder.

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Battery group 2.1

Components BG 2.1 – Screw the lifting eyes into the module holder (1).

DANGER Dangerous electrical voltage!

Voltage is present between the POSITIVE power connectors and the NEGATIVE power connectors.

Touching live components can lead to an electric shock, which can have thermal or paralysing effects.

– Wear personal protective equipment.

– Use insulated tools.

– Secure the POSITIVE power connector against inadvertent contact.

– Secure the positive power connector (3) against inadvertent contact.

WARNING Risk caused by lifting heavy loads!

Manual lifting and handling is permitted only up to a maximum weight of 25 kg.

– Use a suitable hoist or transport vehicle for items above 25 kg.

– Lift the module holder (1), along with the negative power connector (2) and the positive power connector (3), out of the battery tray.

Weight of module holder including modules: approx. 200 kg – Place the module holder (1) on a suitable surface, e.g. a europallet.

Installing DANGER Dangerous electrical voltage!

Battery voltage is present between the POSITIVE power connectors and the NEGATIVE power connectors.

Touching live components can lead to an electric shock, which can have thermal or paralysing effects.

– Wear personal protective equipment.

– Use insulated tools.

WARNING Risk caused by lifting heavy loads!

Manual lifting and handling is permitted only up to a maximum weight of 25 kg.

– Use a suitable hoist or transport vehicle for items above 25 kg.

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21 Components BG 2.1

– Screw the lifting eyes into the module holder (1).

– Place the module holder (1), along with the negative power connector (2) and the positive power connector(3), in the battery tray.

Weight of module holder including modules: approx. 200 kg – Remove the device securing against inadvertent contact from the positive power connector (3).

– Tighten the M6x20 hexagon head screw (1) (negative power connector) and attach the protective cap.

Tightening torque: 9 Nm – Screw the M10 self-securing nut (2) to the decoupler threaded bolt.

Tightening torque: 15 Nm

– Tighten the M10x25 mounting screws (1) of the module holder.

Tightening torque: 15 Nm

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Battery group 2.1

Components BG 2.1 – Tighten the M12x30 clamping bolts (1).

Tightening torque of the clamping bolt: 10 Nm Tightening torque of the lock nut: 40 Nm WARNING Risk caused by lifting heavy loads!

Manual lifting and handling is permitted only up to a maximum weight of 25 kg.

– Use a suitable hoist or transport vehicle for items above 25 kg.

– Place the weight package (2) into the battery tray by hooking onto the M8 lifting eye(3).

Weight: approx. 100 kg – Secure the M16 nuts (1), along with the washers, to the guide rods.

Tightening torque: 100 Nm – Unscrew the lifting eye from the internal thread of the tie rod (3).

– Place the module covers (1) on the battery tray.

– Tighten the M6x12 screws (2).

Tightening torque: 8 Nm – Restore operating status; see the section entitled "Restoring operating status".

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21 Components BG 2.1

Removing/installing the positive power connector DANGER Dangerous electrical voltage!

Voltage is present at the positive power connector.

Touching live components can lead to an electric shock, which can have thermal or paralysing effects.

– Wear personal protective equipment.

– Use insulated tools.

Removing – Remove the module holder; see the section entitled "Removing/installing the module holder".

– Unscrew the M6x12 socket head screws (1) (x18).

– Remove the front module guide plate (2).

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Battery group 2.1

Components BG 2.1 – Disconnect the plugs (1) from the plug connections of the respective modules and pull out the CAN bus cable (2).

NOTE

The positive power connector is inserted into the module connecting plug and can easily be removed without using any further tools.

– Pull the positive power connector (3) together with the plugs (2) forwards out of the plug connections (1) on the modules.

Installing – Wear personal protective equipment.

– Use insulated tools.

– From the front, plug the positive power connector (3) together with the plugs (2) into the plug connections (1) on the modules.

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21 Components BG 2.1

– Insert the CAN bus cable (2) into the adjoining plug connections (1) of the adjacent modules.

– Insert the terminating resistor at the cable end of the CAN bus into the plug connection on the module.

NOTE

The 50 Ω terminating resistor of the CAN bus is not included in the scope of delivery for the new battery module and must be taken from the removed module.

– Position the front module guide plate (2) in front of the module holder.

– Tighten the M6x12 socket head screws (1).

Tightening torque: 9 Nm

Removing/installing the battery module DANGER Dangerous electrical voltage!

Touching live components can lead to an electric shock, which can have thermal or paralysing effects.

– Wear personal protective equipment.

– Use insulated tools.

Special tools required: • Lifting tool • Spanner AF 10

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Battery group 2.1

Components BG 2.1 Removing – Remove the positive power connector; see the section entitled "Removing/installing the positive power connector".

– Remove the power distributor plate (1) from the positive side of the battery module.

WARNING Risk caused by lifting heavy loads!

Manual lifting and handling is permitted only up to a maximum weight of 25 kg.

– Use a suitable hoist or transport vehicle for items above 25 kg.

– Fit the lifting tool to the relevant battery module(1) and pull the module forwards out of the module holder.

Battery module weight: approx. 30 kg – Set the battery module down, ensuring that it is stable.

– Remove the lifting tool.

Installing NOTE

After installing a new battery module, pack the old battery module that you have removed in the packaging used to deliver the new battery module to ensure that it can be safely transported back to the battery module manufacturer.

– Fit the lifting tool.

WARNING Risk caused by lifting heavy loads!

Manual lifting and handling is permitted only up to a maximum weight of 25 kg.

– Use a suitable hoist or transport vehicle for items above 25 kg.

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21 Components BG 2.1

– Bring the battery module to the battery tray and lift it until the battery module (1) is positioned horizontally in front of the battery tray.

– Push the battery module into the module holder from the front.

The centring pins (1) in the battery tray ensure that the plug for the negative power connector (2) engages securely in the plug connection on the underside of the battery module.

The centring holes (2) on the underside of the battery module ensure that the plug connection for the negative power connector (1) engages securely in the plug in the battery tray.

– Check the position in which the respective plug of the negative power connector and the centring pins in the battery tray can be seen.

– Carefully push the battery module horizontally into the tray until it sits firmly in the module holder.

– Make sure that the battery module engages securely and is centred in the installation position.

– Remove the lifting tool.

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Components BG 2.1 – Place the power distributor plates (1) on the battery modules.

– Install the positive power connector; see the section entitled "Removing/installing the positive power connector".

– If a defective battery module has been replaced, pack the defective battery module in the battery module packaging.

CAN bus terminating resistor (120 Ω) The CAN bus is equipped with a terminating resistor (120 Ω). The terminating resistor is plugged into the last plug connector on the CAN bus. Uninterrupted operation cannot be guaranteed without a terminating resistor.

– Pull the terminating resistor (1) out from the plug connection on the removed module.

– Place the terminating resistor (1) at the cable end of the CAN bus into the plug connection on the new module.

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21

Technology compartment BG 2.1 Opening/closing the technology compartment Special tools required: • Hexagon socket wrench AF 5

Opening – Measure the insulation resistance; see the section entitled "Measuring the insulation resistance".

– Unscrew the M6x10 socket head screws (1).

WARNING Risk caused by lifting heavy loads!

Manual lifting and handling is permitted only up to a maximum weight of 25 kg.

– Use a suitable hoist or transport vehicle for items above 25 kg.

– Remove the maintenance cover (2).

Weight: 9 kg

Closing Before fitting the maintenance cover, ensure that: • The cover seal in the battery tray wall is in perfect condition and is positioned correctly in the seal groove • The sealing face of the maintenance cover is clean and undamaged WARNING Risk caused by lifting heavy loads!

Manual lifting and handling is permitted only up to a maximum weight of 25 kg.

– Use a suitable hoist or transport vehicle for items above 25 kg.

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Battery group 2.1

Technology compartment BG 2.1 – Position the maintenance cover (2) in front of the technology compartment.

Weight: 9 kg – Make sure that there are no cables between the maintenance cover (2) and the mounting surface.

– Fit the maintenance cover.

– Tighten the M6x10 socket head screws (1).

Tightening torque: 9 Nm – Measure the insulation resistance; see the section entitled "Measuring the insulation resistance".

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21 Technology compartment BG 2.1

Current/voltage sensor (CVS) The CVS measures the current and voltage and supports the BMS in evaluating the power requirements of the truck.

Tasks in detail: • Measuring the battery current (Messshunt) • Measuring the battery voltage • Temperature measurement Messshunt • Galvanic isolation of 48 V control voltage supply • Measured value transmission to BMC via CAN Voltage measurements: • Measurement of voltage + modules directly after 450 A fuse (S1-) • Measurement of voltage after connected contactor K1 (K1+)

1 2 X71 X72

Battery module connection Battery male connector connection Connection BMC Voltage measurement

• Measurement of output voltage after connected contactor K2 (K2-)

Removing/installing the current/voltage sensor DANGER Dangerous electrical voltage!

Touching live components can lead to an electric shock, which can have thermal or paralysing effects.

– Wear personal protective equipment.

– Use insulated tools.

– De-energise the system.

Special tools required: • Spanner AF 10 • ISO grommet sleeve (insulated grommet, clamping cap)

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Battery group 2.1

Technology compartment BG 2.1 Removing – Ensure that the electrical system is de-energised; see the section entitled "De-energising the system".

– Disconnect the plugs X71 (2) and X72 (3).

– Remove the protective caps (5).

– Unscrew the M6x20 hexagon head screws (4, 6).

– Remove the current/voltage sensor (1).

Securing the CVS conductor rails – Push ISO grommet sleeves onto the positive (1) and negative (2) conductor rails.

Removing the CVS support – Unscrew the M6 ratchet screw (1).

– Remove the CVS support (2).

Installing – Ensure that the electrical system is de-energised; see the section entitled "De-energising the system".

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21 Technology compartment BG 2.1

Installing the CVS support – Insert the CVS support (2).

– Tighten the M6 ratchet screw (1).

Tightening torque: 9 Nm Installing the current/voltage sensor

– Remove the ISO grommet sleeves from the conductor rails.

– Insert the current/voltage sensor (1).

– Tighten the M6x20 hexagon head screws (4, 6).

Tightening torque: 9 Nm – Attach the protective caps (5).

– Connect the plugs X71 (2) and X72 (3).

– Restore operating status; see the section entitled "Restoring operating status".

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Technology compartment BG 2.1 Brake chopper module (BCM) Functional description The BCM monitors battery voltage during truck operation. If the battery voltage exceeds the value of 53.9 V in a 48 V lithium-ion system due to recuperation, the system is automatically activated.

It connects a resistor in parallel with the battery using power electronics. The resistor absorbs the average regenerative power, which keeps the battery voltage constant at approximately 53.7 V. The housing of the BCM includes three LEDs. These indicate the current status of the component independently of the BMC.

1 2 3 4 5 6 7

Connection R+ on brake resistor (+) Connection R- on brake resistor (-) X42 (2-pin) connection on brake resistor NTC temperature sensor BAT- connection X41 (6-pin) connection on brake resistor BMC Status LED BAT+ connection

Status LED

1 2 3

LED

on/off

BCM operating mode

All

Off

Switched off

"enable"

On

Ready

"ready"

On

Active

"ready"

Off

Active - is then switched off

"pre-charge"

On

Pre-charging active

21-38

"enable" LED (enabled by master) "ready" LED (temperature monitoring/performance) "pre-charge" LED

Function Release available, must be performed by the BMC Temperature monitoring of the NTC resistance on the brake resistor within the specified temperature range Temperature monitoring of the NTC resistance on the brake resistor outside the specified temperature range Internal pre-charging of the BCM pre-charge relay by the BMC (must be charged for 200 ms before the main contactors close)

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21 Technology compartment BG 2.1

Enabled by master The "enable" LED (1) indicates the enable status signalled by the BMC. If the LED is illuminated, the enable signal is present.

The BMC can disable the BCM component depending on the truck condition/battery status.

Temperature monitoring/performance The BCM monitors the temperature of the power electronics internally and monitors the temperature of the brake resistor externally with an additional open circuit detector. The two temperature monitors are standardised into a single "performance" parameter. This is transmitted to the BMC via pulse width modulation using PIN "feedback" and indicated by the "ready" LED (2). The pulse width modulation frequency is approx. 10 Hz. The LED is illuminated constantly when the component is performing at 100%. If the LED flashes briefly, this indicates increased performance. If the LED flashes slowly, this indicates decreased performance. If performance is at 0% or if there is a cable break in the external temperature sensor, the LED is off.

Pre-charging The BCM has an internal pre-charge circuit for the intermediate circuit of the BCM. Precharging is controlled by the BMC. The status of the pre-charge path is indicated by the "pre-charge" LED (3). If the LED lights up, pre-charging is active.

Status description There are three internal testing and measurement circuits that function independently of each other. All measurement, detection and control is analogue (performed without software): • Continuous testing for line breakage of the external temperature sensor • Continuous measurement of the performance electronics temperature and the brake resistor as well as adaptation of the feedback signal • Testing the battery voltage and generating switching signals for the power transistors

BCM self-protection The BMC uses the feedback signal from the BCM to adjust the maximum permissible recuperated power to keep the BCM system within the permissible temperature range. If the truck does not adhere to this value, the BCM system switches off automatically to protect itself.

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Technology compartment BG 2.1 Removing/installing the brake chopper module DANGER Dangerous electrical voltage!

Touching live components can lead to an electric shock, which can have thermal or paralysing effects.

– Wear personal protective equipment.

– Use insulated tools.

– De-energise the system.

Special tools required: • Hexagon socket wrench AF 3 • Hexagon socket wrench AF 8 • Hexagon key AF 10

Removing NOTE

The BCM must be removed together with the carrier plate. Otherwise, not all of the screw joints that connect the BCM to the assembly baseplate will be accessible.

– Measure the insulation resistance; see the section entitled "Measuring the insulation resistance".

– Ensure that the electrical system is de-energised; see the section entitled "De-energising the system".

– Disconnect the plug for the NTC temperature sensor at connection X42 (1).

– Disconnect the plug for the BMC signal at connection X41 (4).

– Unscrew the socket head screw (5) from the BAT+ connection and remove the cable from the BMC. – Unscrew the M10x12 (2) socket head screw.

– Remove the BCM/CVS cable (3) from the BCM. – Unscrew the M10x12 (6) socket head screw.

– Remove the BMC/negative brake resistor cable from the BMC. – Unscrew the M10x12 (10) socket head screw.

– Remove the BMC/negative brake resistor cable (9) from the BMC. – Remove the BMC/contactor assembly cable (8) from the BMC.

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21 Technology compartment BG 2.1

– Unscrew the M6 flanged nuts (1).

– Remove the tensioning stabilisers (3).

– Remove the BCM (2) together with the carrier plate (4).

– Unscrew the M4x10 socket head screws (5).

– Remove the BCM from the carrier plate.

Installing – Ensure that the electrical system is de-energised; see the section entitled "De-energising the system".

– Place the BCM (2) on the carrier plate (4).

– Tighten the M4x10 socket head screws (5).

Tightening torque: 2.5 Nm – Insert the BCM together with the carrier plate.

– Fit the tensioning stabilisers (3).

– Tighten the M6 flanged nuts (1).

Tightening torque: 9 Nm

– Place the BCM/CVS cable (3) on the BATconnection.

CAUTION Incorrect assembly can damage the battery!

Incorrectly routed cables can be crushed and cause a short circuit.

– Route cables safely and ensure that they are held in position.

– Tighten the M10x12 socket head screw (2).

Tightening torque: 15 Nm – Place the BAT+ cable (5) on the BAT+ connection and tighten the screw.

Tightening torque: 2.5 Nm – Place the BMC/negative brake resistor cable on the BMC.

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Battery group 2.1

Technology compartment BG 2.1 – Tighten the M10x12 socket head screw (6).

Tightening torque: 15 Nm – Place the BMC/negative brake resistor cable (9) on the BMC. – Place the BMC/contactor assembly cable (8) on the BMC. – Tighten the M10x12 socket head screw (10).

Tightening torque: 15 Nm – Connect the BMC signal plug to the X41 connection (4).

– Connect the NTC temperature sensor to the X42 connection (1).

– Restore operating status; see the section entitled "Restoring operating status".

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21 Technology compartment BG 2.1

Brake resistor 105 mΩ

1

WARNING Danger of burns from the hot brake resistor!

The temperature of the brake resistor can rise to >100 °C during operation. It can take several hours for the brake resistor to cool down to a low hazard temperature. Thermal radiation can also affect other components in and around the technical compartment, which then become hot.

– Do not touch hot surfaces with bare hands.

– Wear protective gloves.

The brake resistor is used to absorb recovered energy (braking energy) if the brake current exceeds the generator voltage of the traction motor.

The NTC resistor monitors the temperature and provides feedback to the brake chopper module.

Technical data Resistance value Resistance value tolerance Insulation resistance Operating voltage

105 mΩ

>50 MΩ UMAX = 54 V (48 V)

Nominal voltage

Unominal = 13 x 3.75 V

Final charged voltage

13 x 4.12 V

4

3

2 386_609-001

1 2 3 4

Brake resistor 105 mΩ Connection to BCM "R-" Connection to BCM "R+" Connection to contactor connectors "K1"/"K2"

±10%

Test voltage (1 minute) UP = 1200 V DC NTC resistance Dimensions (length / width / height)

10 kΩ 503 mm / 100 mm / 50 mm

.

Removing/installing the brake resistor DANGER Dangerous electrical voltage!

Touching live components can lead to an electric shock, which can have thermal or paralysing effects.

– Wear personal protective equipment.

– Use insulated tools.

– De-energise the system.

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Battery group 2.1

Technology compartment BG 2.1 WARNING Risk of burns from the hot brake resistor!

The temperature of the brake resistor can rise to >100°C during operation. It can take several hours for the brake resistor to cool down to a temperature at which it poses a low risk. The heat can also radiate to other components in and around the technology compartment, which then become hot.

– Do not touch hot surfaces with bare hands.

– Wear protective gloves.

Special tools required: • Hexagon socket wrench AF 6 • Hexagon socket wrench AF 8

Removing – Measure the insulation resistance; see the section entitled "Measuring the insulation resistance".

– Ensure that the electrical system is de-energised; see the section entitled "De-energising the system".

– Remove the brake chopper module; see the section entitled "Removing/installing the brake chopper module".

– Unscrew the M8x18 socket head screws (1) from the holding plate (2).

– Remove the holding plate (2).

– Carefully remove the brake resistor (3).

CAUTION Risk of damage as a result of the forces applied to cable glands!

Pulling on the connecting cables can cause damage to the cable glands of the brake resistor.

– Remove the brake resistor by pulling directly on the cable glands.

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21 Technology compartment BG 2.1

Installing – Insert the brake resistor (1) in the right-hand side of the guide (2).

– Push the brake resistor (3) all the way in.

– Place the holding plate (2) in front of the brake resistor.

– Tighten the M8x18 socket head screws (1).

Tightening torque: 12 Nm – Install the brake chopper module; see the section entitled "Removing/installing the brake chopper module".

– Restore operating status; see the section entitled "Restoring operating status".

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Battery group 2.1

Technology compartment BG 2.1 Battery master controller (BMC) The BMC determines the charge and overall condition of all the battery cells. It communicates with the industrial truck via the CAN bus and with the CSC via the internal CAN bus.

Tasks in detail: • Activation of the main contactors, K1 and K2 • Monitoring of the battery modules • Safety monitoring function of the battery modules • Communication with the truck control unit • Communication with the battery display and the shock sensor • Communication with the BCM

1 2 3 X11 X12 X13 X14

LEDs (x2), BMC main processor BMC LEDs (2 pieces) BMC monitoring computer Diagnostics, CAN, contactors, BCM, SSV CSC Battery display / shock sensor Power supply

LED codes BMC LEDs Off Flashing white

Computer BMC Main processor and monitoring processor Main processor and monitoring processor

Flashing white + blue

Main processor

Solid white + blue

Main processor

Solid blue

Monitoring processor

Flashes blue once

Monitoring processor

.

Removing/installing the battery master controller DANGER Dangerous electrical voltage!

Touching live components can lead to an electric shock, which can have thermal or paralysing effects.

– Wear personal protective equipment.

– Use insulated tools.

– De-energise the system.

Special tools required: • Spanner AF 10

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Operating status Quiescent state Ready, charging or driving Self testing, emergency operation, error with error analysis Malfunction (with error, including up to shut-off 1) Feedback signal deactivated Normal operation, feedback signal test

Battery group 2.1

21 Technology compartment BG 2.1

Removing – Measure the insulation resistance; see the section entitled "Measuring the insulation resistance".

– Ensure that the electrical system is de-energised; see the section entitled "De-energising the system".

– Disconnect the plugs X11 (5), X12 (4), X13 (3) and X14 (6).

– Unscrew the M6x16 ratchet screws (1).

– Remove the battery master controller (2) together with the carrier plate (7).

Installing – Fit the battery master controller (2) together with the carrier plate (7).

– Tighten the M6x16 ratchet screws (1).

Tightening torque: 9 Nm – Connect the plugs X11 (5), X12 (4), X13 (3) and X14 (6).

– Restore operating status; see the section entitled "Restoring operating status".

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Battery group 2.1

Technology compartment BG 2.1 Control voltage supply (SSV) The SSV supplies the truck electrics before the battery is switched on, and ensures a continuous power supply to the DC/DC converter. The power transmission path used to supply control units with power has a 20 A fuse on the output side.

X51 - pin assignment: • PIN 1 Blocking signal from BMC • PIN 2 Negative X52 - pin assignment: • PIN 1 Negative connection • PIN 2 Battery positive connection before switch-on contactor

F50 X51 X52

20 A fuse Plug connection Plug connection

• PIN 3 Control voltage to truck • PIN 4 Battery positive connection to battery voltage transformer Tasks in detail: • Supplies the truck electrics before the battery is switched on • Switches the power supply off after the battery is switched off • Switches off the battery supply voltage in the event of under voltage • Switches off the battery supply voltage from BMC • Switches off the complete power supply • Limits the control current to the truck • Prevents battery charging from the control voltage (voltage feedback protection)

Removing/installing the control voltage supply unit DANGER Dangerous electrical voltage!

Touching live components can lead to an electric shock, which can have thermal or paralysing effects.

– Wear personal protective equipment.

– Use insulated tools.

– De-energise the system.

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21 Technology compartment BG 2.1

Special tools required: • Spanner AF 10

Removing – Measure the insulation resistance; see the section entitled "Measuring the insulation resistance".

– Ensure that the electrical system is de-energised; see the section entitled "De-energising the system".

– Remove the battery master controller (BMC); see the section entitled "Removing/installing the battery master controller".

– Disconnect the plug X52 (1) and the plug X51 (2).

– Unscrew the M6 flanged nuts (3).

– Remove the control voltage supply unit (SSV) (4).

Installing – Insert the control voltage supply unit (SSV) (4).

– Tighten the M6 flanged nuts (3).

– Tightening torque: 9 Nm – Connect the plug X52 (1) and the plug X51 (2).

– Install the battery master controller (BMC); see the section entitled "Removing/installing the battery master controller".

– Restore operating status; see the section entitled "Restoring operating status".

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Battery group 2.1

Technology compartment BG 2.1 Contactor assembly When commissioning the truck, the contactors are enabled as long as the battery is ready for operation.

1 2 3

Contactor K1 Connector plug X94 Contactor K2

Removing/installing the contactor assembly DANGER Dangerous electrical voltage!

Touching live components can lead to an electric shock, which can have thermal or paralysing effects.

– Wear personal protective equipment.

– Use insulated tools.

– De-energise the system.

Special tools required: • Spanner AF 10 • Spanner AF 15

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21 Technology compartment BG 2.1

Removing – Ensure that the electrical system is de-energised; see the section entitled "De-energising the system".

– Remove the protective cap (1).

– Disconnect the plug X94 (2).

Removing the connector between contactor K1/contactor K2 – Unscrew the M10 flanged nut (2).

– Remove the connector between the brake resistor/contactor bridge (4) from the threaded bolt (2).

– Unscrew the M10 flanged nut (1).

– Remove the connector between contactor K1/contactor K2 (3) from the threaded bolt.

The electrical connection between contactor K1 (5) and contactor K2 (6) is now broken.

Removing the connector between contactor K1/main positive connection – Unscrew the M10 flanged nut (2).

– Remove the connector between contactor K1/main positive connection (3) from the threaded bolt (2).

The electrical connection between contactor K1 (1) and the main positive connection is now broken.

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Battery group 2.1

Technology compartment BG 2.1 Removing the connector between contactor K2/main positive connection – Unscrew the M10 flanged nut (2).

– Remove the protective cap and unscrew the M10 flanged nut (3).

– Remove the connector between contactor K2/main positive connection (4).

The electrical connection between contactor K2 (1) and the main positive connection is now broken.

Removing the contactor bridge – Unscrew the M6 hexagon nuts (1).

– Remove the contactor bridge (2) with contactors.

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21 Technology compartment BG 2.1

Removing contactor K1 and contactor K2 – Unscrew the M6 flanged nuts (2).

– Remove contactor K1 (3) and contactor K2 (4) from the contactor bridge (1).

Installing

Fitting contactor K1 and contactor K2 – Fit contactor K1 (3) and contactor K2 (4) to the contactor bridge (1).

– Tighten the M6 flanged nuts (2).

Tightening torque: 9 Nm

Installing the contactor bridge – Place the contactor bridge (2) on the rear wall of the technology compartment.

– Tighten the M6 hexagon nuts (1).

Tightening torque: 9 Nm

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21

Battery group 2.1

Technology compartment BG 2.1 Installing the connector between contactor K2/main positive connection – Fit the connector between contactor K2/main positive connection (4) onto the threaded bolts (2) at the contactor K2 (1).

– Fit the connector between contactor K2/main positive connection (4) onto the threaded bolts (3) at the main positive connection (3).

– Tighten the M10 flanged nut (3).

Tightening torque: 15 Nm – Tighten the M10 flanged nut (2).

Tightening torque: 15 Nm

Installing the connector between contactor K1/main positive connection – Fit the connector between contactor K1/main positive connection (3) onto the threaded bolts (2) at the contactor K1 (1).

– Align the connector between contactor K1 /positive main connection with the threaded hole on the positive main connection.

– Tighten the M10x20 hexagon head screw (2).

Tightening torque: 15 Nm

Installing the connector between contactor K1/contactor K2 – Fit the connector between contactor K1/contactor K2 (3) onto the threaded bolts (1) above contactor K1 (5) and contactor K2 (6).

– Tighten the M10 flanged nut (1).

Tightening torque: 15 Nm – Fit the connector between the brake resistor/contactor bridge (4) onto the threaded bolts (2) on the connector between contactor K1/contactor K2.

– Tighten the M10 flanged nut (2).

Tightening torque: 15 Nm

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21 Technology compartment BG 2.1

– Connect the plug X94 (2).

– Attach the protective cap (1).

– Restore operating status; see the section entitled "Restoring operating status".

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Battery group 2.1

Technology compartment BG 2.1 Voltage transformer (DC/DC) The DC/DC voltage transformer ensures a permanent power supply to the BMC and the diagnostic interface.

• Input voltage 48 V from SSV • 12 V output voltage • Supply from: BMC CSC CVS Battery display / shock sensor

1 2

DC/DC voltage transformer Plug connection

Removing/installing the voltage transformer DANGER Dangerous electrical voltage!

Touching live components can lead to an electric shock, which can have thermal or paralysing effects.

– Wear personal protective equipment.

– Use insulated tools.

– De-energise the system.

Special tools required: • Hexagon socket wrench AF 4 • Spanner AF 10

Removing – Measure the insulation resistance; see the section entitled "Measuring the insulation resistance".

– Ensure that the electrical system is de-energised; see the section entitled "De-energising the system".

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21 Technology compartment BG 2.1

– Disconnect the connector plug (3) from the voltage transformer (2).

– Unscrew the M6x16 ratchet screws (3).

– Remove the voltage transformer (2).

Installing – Position the voltage transformer (2) on the rear wall of the technology compartment.

– Tighten the M6x16 ratchet screws (3).

Tightening torque: 9 Nm – Connect the connector plug (3) to the voltage transformer (2).

– Restore operating status; see the section entitled "Restoring operating status".

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Battery group 2.1

Technology compartment BG 2.1 Electrical fuses Main fuse The main fuse on the positive power distribution side has a rating of 450 A.

1 F1

Fuse holder Main fuse (450 A)

1 F2 F3 F4 F5 F6

Fuse holder BMC / SSV (20 A) CVS voltage measurement S1- (3 A) CVS voltage measurement S2+ (3 A) CVS voltage measurement S2- (3 A) Pre-charging for the brake chopper (3 A)

Control current fuses The control current is protected by blade fuses in the fuse holder.

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21 Technology compartment BG 2.1

Blade fuses on the SSV

1

F20 386_609-015

1 F50

SSV Control units supply (20 A) power transmission path (output side)

Replacing electrical fuses DANGER Dangerous electrical voltage!

Touching live components can lead to an electric shock, which can have thermal or paralysing effects.

– Wear personal protective equipment.

– Use insulated tools.

– De-energise the system.

Special tools required: • Torque wrench AF 15 • Fuse puller for auto plug-in fuse

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Battery group 2.1

Technology compartment BG 2.1 Replacing the main fuse CAUTION Risk of damage to the contactors by triggering the main fuse.

Triggering the main fuse may cause "short-circuit current" that can damage the contactors.

– After the main fuse has been triggered, the contactors must be replaced.

– Measure the insulation resistance; see the section entitled "Measuring the insulation resistance".

– Ensure that the electrical system is de-energised; see the section entitled "De-energising the system".

1 F1

Fuse holder Main fuse (450 A)

– Remove the protective caps (1).

– Unscrew the M10x20 ratchet screws (2).

– Remove the main fuse (3).

– Insert a new main fuse with the same nominal current.

– Tighten the M10x20 ratchet screws (2).

Tightening torque: 18 Nm – Attach the protective caps (1).

– Restore operating status; see the section entitled "Restoring operating status".

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21 Technology compartment BG 2.1

Replacing the control current fuses Control current fuses in the fuse holder – Measure the insulation resistance; see the section entitled "Measuring the insulation resistance".

– Ensure that the electrical system is de-energised; see the section entitled "De-energising the system".

– Locate any defective auto plug-in fuses (F2F6) and remove them from the fuse holder (1) using a fuse puller.

– Insert a new auto plug-in fuse with the same nominal current.

– Restore operating status; see the section entitled "Restoring operating status".

1 F2 F3 F4 F5 F6

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Fuse holder BMC / SSV (20 A) CVS voltage measurement S1- (3 A) CVS voltage measurement S2+ (3 A) CVS voltage measurement S2- (3 A) Pre-charging for the brake chopper (3 A)

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Battery group 2.1

Wiring BG 2.1 Removing/installing the power cable DANGER Dangerous electrical voltage!

Touching live components can lead to an electric shock, which can have thermal or paralysing effects.

– Wear personal protective equipment.

– Use insulated tools.

Special tools required: • Hexagon socket wrench AF 5 • Spanner AF 22

1 2 3 4 5

Battery male connector for the industrial truck Tray cover Communication connection Positive power connection Negative power connection

Removing – Measure the insulation resistance; see the section entitled "Measuring the insulation resistance".

– Unscrew the M10x47 terminal bolt (1) from the positive power connection (6).

– Unscrew the M10x47 terminal bolt (4) from the negative power connection (5).

– Pull out the communication plug (7).

– Pull the positive power cable (2), the negative power cable (3) and the communication cable (7) upwards and out of the cable channel.

Installing – Pull the positive power cable (2), the negative power cable (3) and the communication cable (7) into the cable channel from above.

– Screw the M10x47 terminal bolt (1) along with the positive power cable (2) onto the positive power connection (6).

Tightening torque: 15 Nm – Screw the M10x47 terminal bolt (4) along with the negative power cable (3) onto the negative power connection (5).

Tightening torque: 15 Nm

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21 Wiring BG 2.1

– Insert the communication plug (7).

– Measure the insulation resistance; see the section entitled "Measuring the insulation resistance".

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Wiring BG 2.1

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22

a

Design BG 2.2 Technical data for battery group 2.2

Parameter Cell connection Nominal energy

Unit Serial/parallel

Value 13 / 15

kWh

48.99

Nominal capacity

Ah

1005

Nominal voltage

V

48.75

Final charged voltage

V

53.6

Final discharged voltage

V

35.1

Discharge current (maximum)

A

400

Discharge power (maximum)

kW

18

Dimensions and weights

Unit mm

Value

mm

529

mm kg

627

Length Width Height Weight

1030

839

Safety Protection class Fire protection rating

IP6K9K External housing/13S cell module

A2/B2

.

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22

Battery group 2.2

Design BG 2.2 Design - Battery group 2.2 1

2

3 11

4

10

5

9

8

6 7

22-2

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386_691-002

Battery group 2.2

22 Design BG 2.2

1 2 3 4 5 6

Metal rail Tray cover Module Technology compartment Connections for power, communication and diagnostics Service flap

7 8 9 10 11

Space for power and communication connections Tray Negative side power connector Power cables Positive side power connector

The batteries are divided into three main assemblies: • Tray structure with cover, modules and power connector • Power and communication connection structure • Technology compartment and service flap structure

Battery safety Battery safety is ensured by the following properties: • 25-mm steel housing • Master controller collects measured data from the slave controller CANs • Two main contactors • Main current fuse in the positive circuit • LCD status display • Brake resistor, brake chopper • Communication with the truck control unit • High-pressure relief valve on battery base

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Battery group 2.2

Design BG 2.2 Technical compartment - battery group 1.1 / 1.2

386_691-001

A B C D E F G H

22-4

Brake resistor Brake chopper module (BCM) Current/voltage sensor (CVS) Battery master controller (BMC) Control voltage supply (SSV) Voltage transformer (DC/DC) Battery display Contactor K1

I J K L M N O P

Contactor K2 Main fuse Control current fuses Pressure equalising element Diagnostic plug X33 Communications plug X34 Positive power connection (+) Negative power connection (-)

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22

De-energised state BG 2.2 Measuring the insulation resistance The insulation measurement steps described below must be carried out on the battery before and after any repair work.

DANGER Dangerous electrical voltage!

Touching live components can lead to an electric shock, which can have thermal or paralysing effects.

– Wear personal protective equipment.

– Use insulated tools.

Special tools • Personal protective equipment • Insulation measuring device

Measuring the insulation resistance – Disconnect the battery male connector from the industrial truck.

– Set the insulation tester to U = 500 V DC. During the test, the BMS must be connected and the contactors must be open (perform the insulation testing anyway if the contactors are stuck).

– Connect the insulation tester to an unpainted socket head screw (1) on the maintenance cover (2), and to the negative terminal of the truck plug (3).

– Measure the insulation resistance.

The insulation resistance (Riso) must be > 1 MΩ.

– Connect the insulation tester to an unpainted socket head screw (1) on the maintenance cover (2), and to the positive terminal of the truck plug (3).

– Measure the insulation resistance.

The insulation resistance (Riso) must be > 1 MΩ.

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Battery group 2.2

De-energised state BG 2.2 Spannungsfreiheit im Technikraum herstellen DANGER Gefährliche elektrische Spannung!

Durch Berührung stromführender Bauteile kann es zu einem elektrischen Schlag kommen, der thermische oder muskellähmende Auswirkungen haben kann.

– Persönliche Schutzausrüstung anziehen.

– Isoliertes Werkzeug verwenden.

Spezialwerkzeuge • Persönliche Schutzausrüstung • Innensechskantschlüssel SW 4 • Sicherungszieher • Drehmomentschlüssel SW 15 • Zweipoliger Spannungsprüfer nach DIN VDE 0682-401:2011-02 (DIN EN 61243-3) • Sicherheitsvorrichtung (Teilenummer: 0009418815)

Technikraum öffnen – Isolationswiderstand messen, siehe Abschnitt "Isolationswiderstand messen".

– Schrauben M6x10 (1) herausschrauben.

WARNING Gefahr durch Heben schwerer Lasten!

Das Heben und Tragen von Hand ist nur bis zu einem Gewicht von max. 25 kg zulässig.

– Oberhalb 25 kg geeignete Hebezeuge oder Fördermittel verwenden.

– Servicedeckel (2) abbauen.

Gewicht: 17 kg

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22 De-energised state BG 2.2

Flachstecksicherung F2 ziehen WARNING Beim ziehen der Sicherung unter Spannung kann ein kleiner Störlichtbogen entstehen.

– Sicherung mit Sicherungszieher entfernen.

– Flachstecksicherung F2 (1) ziehen.

Hauptsicherung ausbauen DANGER Gefährliche elektrische Spannung!

Am Plus-Sicherungseingang liegt weiterhin Spannung an.

Durch Berührung stromführender Bauteile kann es zu einem elektrischen Schlag kommen, der thermische oder muskellähmende Auswirkungen haben kann.

– Persönliche Schutzausrüstung anziehen.

– Isoliertes Werkzeug verwenden.

– Schutzkappen (wenn vorhanden) (1) abziehen.

– Sperrzahnschrauben M10x20 (2) herausschrauben – Hauptsicherung (3) entfernen.

DANGER Gefährliche elektrische Spannung!

Am Plus-Sicherungseingang liegt weiterhin Spannung an.

Verhinderung von versehentlichem Berühren oder Kurzschließen der noch spannungsführenden Eingangsseite der Hauptsicherung.

– Bei Reparaturen im Technikraum der Batterie muss nach dem Entfernen der Hauptsicherung die isolierte Sicherheitsvorrichtung angebracht werden.

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Battery group 2.2

De-energised state BG 2.2 – Stromschiene (1) mit Sicherheitsvorrichtung (2) abdecken.

Spannungsfreiheit im Technikraum prüfen – Zweipoliger Spannungsprüfer an CVS-Minus (3) gegen Plus-Sicherungseingang (1) anlegen.

Prüfergebnis: Elektrische Spannung anliegend.

– Zweipoliger Spannungsprüfer an CVS-Minus (3) und Plus-Sicherungsausgang (2) prüfen.

Prüfergebnis: Keine elektrische Spannung anliegend.

Beriebszustand wiederherstellen DANGER Gefährliche elektrische Spannung!

Durch Berührung stromführender Bauteile kann es zu einem elektrischen Schlag kommen, der thermische oder muskellähmende Auswirkungen haben kann.

– Persönliche Schutzausrüstung anziehen.

– Isoliertes Werkzeug verwenden.

Spezialwerkzeuge • Persönliche Schutzausrüstung • Innensechskantschlüssel SW 4 • Isolationsmessgerät 22-8

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22 De-energised state BG 2.2

• Sicherungszieher • Drehmomentschlüssel SW 15 • Zweipoliger Spannungsprüfer nach DIN VDE 0682-401:2011-02 (DIN EN 61243-3)

Hauptsicherung einbauen DANGER Gefährliche elektrische Spannung!

Am Plus-Sicherungseingang liegt weiterhin Spannung an.

Durch Berührung stromführender Bauteile kann es zu einem elektrischen Schlag kommen, der thermische oder muskellähmende Auswirkungen haben kann.

– Persönliche Schutzausrüstung anziehen.

– Isoliertes Werkzeug verwenden.

– Sicherheitsvorrichtung (2) von der Stromschiene (1) abnehmen.

– Hauptsicherung (3) anbauen.

– Sperrzahnschrauben M10x20 (2) festschrauben Anzugsdrehmoment: 18 Nm – Schutzkappen (wenn vorhanden) (1) aufstecken.

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Battery group 2.2

De-energised state BG 2.2 Flachstecksicherung F2 einsetzen – Flachstecksicherung F2 (1) einstecken.

NOTE Wenn die SSV nach wiedereinsetzen der Flachstecksicherung F2 nicht automatisch startet, muss die SSV manuell neu gestartet werden.

Dazu den Reset-Taster auf der SSV drücken.

Technikraum schließen WARNING Gefahr durch Heben schwerer Lasten!

Das Heben und Tragen von Hand ist nur bis zu einem Gewicht von max. 25 kg zulässig.

– Oberhalb 25 kg geeignete Hebezeuge oder Fördermittel verwenden.

– Servicedeckel (2) anbauen.

Gewicht: 17 kg – Schrauben M6x10 (1) über Kreuz festschrauben.

Anzugsdrehmoment: 9 Nm – Isolationswiderstand messen, siehe Abschnitt "Isolationswiderstand messen".

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22

Components BG 2.2 Tray cover - Battery group 2.2 Unit mm

1030

Width Height

mm

502

mm

22

Screw joint

Piece

29

Length

Value

NOTE

The different types of cover design are not interchangeable.

1 2 3 4 5

Battery tray cover Bore for cover screw joint Cover seal Recess for lifting eyes Duct for battery cable

Trogdeckel Abbau/Anbau Benötigte Spezialwerkzeuge: • Innensechskantschlüssel SW 5

Abbau – Isolationswiderstand messen, siehe Abschnitt "Isolationswiderstand messen".

– Leistungskabel und Kommunikationskabel ausbauen siehe Abschnitt "Leistungskabel Ausbau/Einbau".

– Zylinderschraube M6x25 (1) herausschrauben.

– Deckelschiene (3) abnehmen.

– Vorgang auf der gegenüberliegenden Deckelseite wiederholen.

– Zylinderschraube M6x25 (5) mit Unterlegblech herausschrauben.

– Vorgang auf der gegenüberliegenden Deckelseite wiederholen.

– Zylinderschraube M6x25 (2) mit Unterlegblech-Kabelschacht herausschrauben.

– Trogedeckel (4) abheben.

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Battery group 2.2

Components BG 2.2 – Sicherstellen, dass beim Ablegen des Trogdeckels die Deckedichtung unterhalb des Trogdeckels nicht beschädigt wird.

Anbau Vor dem Auflegend es Trogdeckels sichterstellen: • Die Deckeldichtung ist einwandfrei und sitzt korrekt in der Dichtungsnut auf der Unterseite des Trogdeckels.

• Die Kabeldurchführung des Trogedeckels liegt über dem Kabelschacht der Anschlüsse Leistung und Kommunikation.

• Die Dichtfläche des Batterietrogs ist sauber und frei von Gegenständen.

– Trogedeckel (4) auflegen.

– Sicherstellen, dass der Trogdeckel umlaufend bündig abschließt und sich nichts zwischen der Deckeldichtung und der Dichtfläche des Batterietrogs befindet.

CAUTION Bauteilbeschädigung oder Undichtigkeit des Trogdeckels möglich!

Der Trogdeckel kann durch ungleichmäßiges Anziehen der Befestigungsschrauben verziehen und die Deckeldichtung undicht werden.

– Zuerst alle Befestigungsschrauben von Hand bis zur Kopfauflage hineinschrauben.

– Befestigungsschrauben immer von der Mitte beginnend nach außen festschrauben.

– Unterschiedliche Anzugsdrehmomente beachten!

– Zylinderschraube M6x25 (2) mit Unterlegblech-Kabelschacht hineinschrauben.

– Zylinderschraube M6x25 (5) mit Unterlegblech hineinschrauben.

– Vorgang auf der gegenüberliegenden Deckelseite wiederholen.

– Deckelschiene (3) auflegen.

– Zylinderschraube M6x25 (1) hineinschrauben.

– Vorgang auf der gegenüberliegenden Deckelseite wiederholen.

– Zylinderschrauben M6x25 (1) von der Mitte beginnend nach außen festschrauben.

Anzugsdrehmoment: 15 Nm – Zylinderschrauben M6x25 (5) von der Mitte beginnend nach außen festschrauben.

Anzugsdrehmoment: 9 Nm – Zylinderschraube M6x25 (2) festschrauben.

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22 Components BG 2.2

Anzugsdrehmoment: 9 Nm – Leistungskabel und Kommunikationskabel einbauen, siehe Abschnitt "Leistungskabel Ausbau/Einbau".

Battery display

1

Charging state LEDs The battery display is switched on when the battery is communicating with the truck, the battery charger or the diagnostic device. The charging state LEDs (3) indicate the charging state of the battery. All charging state LEDs (3) light up green in sequence when the battery is charging.

Display

Charging state Comment (%) First charging state LED flashes red: 0-2 the truck can no longer be moved.

First charging state LED lights up red: drive to > 2 - 10 the charging station immediately

3

2 386_609-007

1 2 3

Service LED Temperature LED Charging state LED

> 10 - 20 > 20 - 30 > 30 - 40 > 40 - 50 > 50 - 60 > 60 - 70 > 70 - 80 > 80 - 90 > 90 - 100 .

Service LED If the service LED (1) lights up, battery function is significantly restricted or operation is not possible. The service LED goes out as soon as the fault is no longer present.

Temperature LED The temperature LED (2) indicates an increased battery temperature. Battery power is reduced or switched off. The temperature LED remains

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Battery group 2.2

Components BG 2.2 active for the run-on time or until the normal temperature range is reached again.

Temperature Slightly Flashing yellow increased (> 60°C) Increased (> Solid yellow 65°C) Significantly Flashing red increased (> 70°C) Greatly increased Solid red (> 75°C) LED status

Result Power reduction Shut-off Shut-off Shut-off

.

Batterie-Display Ausbau/Einbau DANGER Gefährliche elektrische Spannung!

Durch Berührung stromführender Bauteile kann es zu einem elektrischen Schlag kommen, der thermische oder muskellähmende Auswirkungen haben kann.

– Persönliche Schutzausrüstung anziehen.

– Isoliertes Werkzeug verwenden.

– Spannungsfreiheit herstellen.

Benötigte Spezialwerkzeuge: • Innensechskantschlüssel SW 3 • Isoliermatte nach DIN VDE 0682-511 [EN/IEC 61112], 1000 V • Berührungsschutz Stromschiene • Persönliche Schutzausrüstung (PSA)

Ausbau – Isolationswiderstand messen, siehe Abschnitt "Isolationswiderstand messen".

– Sicherstellen, dass die elektrische Anlage spannungsfrei ist, siehe Abschnitt "Spannungsfreiheit herstellen".

– Trogdeckel abbauen, siehe Abschnitt "Trogdeckel Abbau/Anbau".

– Leistungsverbinder Plus ausbauen, siehe Abschnitt "Leistungsverbinder Plus Ausbau/Einbau".

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22 Components BG 2.2

– Spannungsführende Teile im Batterietrog (1) mit Isoliermatte (3) abdecken.

– Entkopplerbolzen (2) gegen unbeabsichtigtes Berühren sichern.

– Spannungswandler ausbauen, siehe Abschnitt "Spannungswandler Ausbau/Einbau".

– Stecker X1 (1), X2 (2) und Verbindungskabel Batterie-Display/Displayelektronik (3) trennen.

– Zylinderschraube M4x10 (5) mit Sicherungsscheibe herausschrauben.

– Displayelektronik (4) entnehmen.

– Zylinderschraube M4x6 (3) mit Sicherungsscheibe herausschrauben.

– Haltebrücke (2) mit Batterie-Display (1) nach innen drücken und entnehmen.

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Battery group 2.2

Components BG 2.2 – Verbindungskabel Batterie-Display/Displayelektronik (3) vom Batterie-Display (1) trennen.

– Eine einwandfreie Dichtung (2) auf dem Batterie-Display belassen, nicht abziehen!

CAUTION Beschädigung der Dichtung möglich!

Die Dichtung ist mit dem dichtungseigenen Klebestreifen auf dem Batterie-Display fixiert. Beim Abziehen kann die Dichtung beschädigt oder zerstört werden und der Klebestreifen verliert seine Haftfähigkeit. Die Dichtung nur abziehen, wenn diese beschädigt ist und eine neue Dichtung zur Montage vorliegt.

– Einwandfreie Dichtung auf dem Batterie-Display belassen.

– Abgezogene oder beschädigte Dichtung durch eine neue Dichtung ersetzen.

Einbau – Sicherstellen, dass die elektrische Anlage spannungsfrei ist, siehe Abschnitt "Spannungsfreiheit herstellen".

Beim Wiedereinbau des vorher ausgebauten Batterie-Displays gilt: – Prüfen, ob die Batterie-Displaydichtung (2) unbeschädigt und wiederverwendbar ist. Ansonsten durch eine neue Dichtung ersetzen.

Beim Ersetzen des ausgebauten Batterie-Displays durch ein neues Batterie-Display gilt: – Schutzfolie von der Vorderseite des neuen Batterie-Displays (1) abziehen.

– Schutzfolie von der Klebefläche der neuen Dichtung (2) abziehen.

– Dichtung auf der Vorderseite des BatterieDisplays umlaufend gleichmäßig ausrichten und leicht auf dem Glaskörper andrücken.

– Verbindungskabel Batterie-Display/Displayelektronik (3) auf der Rückseite des Batterie-Displays (1) anschließen.

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22 Components BG 2.2

– Haltebrücke (2) mit Batterie-Display (1) und aufgeklebter Dichtung in die Ausfräsung hineinschieben.

– Zylinderschraube M4x6 (3) mit Sicherungsscheibe festschrauben.

Anzugsdrehmoment: 2,5 Nm

– Displayelektronik (4) mit den Steckeranschlüssen (1, 2) nach oben an der Trogwand ausrichten.

– Verbindungskabel Batterie-Display/Displayelektronik (3) zwischen der Displayelektronik (4) und der Trogwand nach oben führen.

– Verbindungskabel Batterie-Display/Displayelektronik an den Steckeranschluss (6) anschließen.

– Zylinderschraube M4x10 (5) mit Sicherungsscheibe festschrauben.

Anzugsdrehmoment: 2,5 Nm – Stecker X1 (1) und X2 (2) anschließen.

– Spannungswandler einbauen, siehe Abschnitt "Spannungswandler Ausbau/Einbau".

– Berührungsschutz vom Entkopplerbolzen (2) entfernen.

– Isolliermatte (3) vom Batterietrog nehmen.

– Leistungsverbinder Plus anbauen, siehe Abschnitt "Leistungsverbinder Plus Ausbau/Einbau".

– Trogdeckel anbauen, siehe Abschnitt "Trogdeckel Abbau/Anbau".

– Betriebszustand wiederherstellen, siehe Abschnitt "Beriebszustand wiederherstellen".

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22

Battery group 2.2

Components BG 2.2 Schocksensor Der Schocksensor teilt sich die Platine mit dem Display und ist mechanisch starr an den Batterietrog angebunden.

G (m/s²)

Ein Schockereignis während der Ruhephase (Lagerung oder Transport) wird ebenfalls registriert und gespeichert.

Batterie im Flurförderzeug verbaut Schocklevel ≤ 10 G

10 G - 15 G

>15 G

Reaktion Ergebnis wird nicht im Fehlerspeicher der Batterie gespeichert.

Speichern des Ereignisses im Fehlerspeicher der Batterie, Senden von CANNachricht an das Fahrzeug, Reduzierung der Fahrgeschwindigkeit Starten der Batterie nicht möglich, Reset durch Servicetechniker nötig.

Transport der Batterie Schocklevel

>15 G

Reaktion Starten der Batterie nicht möglich, Reset durch Servicetechniker nötig.

Fehler kann über die Diagnose nicht zurückgesetzt werden.

.

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50988012057 EN - 12/2017

15 G 10 G t (min) 386_609-012

Battery group 2.2

22 Components BG 2.2

Pressure equalising element

1

The pressure equalising element is part of the safety concept of the battery system.

In normal operation, the membrane (3) equalises internal and external pressures.

The pressure cap (2) is connected to the housing (1) by a bayonet catch. If a critical over pressure (4) is reached, the pressure cap is pushed from the housing and the over pressure escapes.

4

2

3 386_691-024

1 2 3 4

Housing Pressure cap with bayonet catch Membrane Pressure "P"

Visual inspection – Unscrew the M6x12 countersunk screws (2) from the maintenance cover (1).

– Remove the maintenance cover.

– Check that the pressure cap (1) is securely attached.

Pressure cap secure: If the pressure cap is firmly seated in the bayonet catch, no critical over pressure has occurred within the battery.

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22

Battery group 2.2

Components BG 2.2 – Place the maintenance cover (1) into the recess in the tray.

– Tighten the M6x12 hexagon head screws (2).

Tightening torque: 8 Nm Pressure cap loose: If the pressure cap is loose, a critical over pressure has occurred within the battery. A critical over pressure is caused by a serious defect within the battery. In the event of this happening, the battery must be tested by the manufacturer and repaired.

– Do not place the battery back in service; inform the battery manufacturer.

Leistungsverbinder Plus Ausbau/Einbau DANGER Gefährliche elektrische Spannung!

Am Leistungsverbinder Plus liegt Spannung an.

Durch Berührung stromführender Bauteile kann es zu einem elektrischen Schlag kommen, der thermische oder muskellähmende Auswirkungen haben kann.

– Persönliche Schutzausrüstung anziehen.

– Isoliertes Werkzeug verwenden.

Benötigte Spezialwerkzeuge: • Schraubenschlüssel SW 17

Ausbau – Isolationswiderstand messen, siehe Abschnitt "Isolationswiderstand messen".

– Spannungsfreiheit herstellen, siehe Abschnitt "Spannungsfreiheit herstellen".

– Trogdeckel abbauen, siehe Abschnitt "Trogdeckel Abbau/Anbau".

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50988012057 EN - 12/2017

Battery group 2.2

22 Components BG 2.2

– Stecker (3) aus den Steckeranschlüssen (2) der betreffenden Module lösen und das CAN-Bus Kabel (1) abziehen.

– Selbstsichernde Mutter M10 vom EntkopplerGewindebolzen (1) abschrauben.

– Kontaktzunge Leistungsverbinder Plus(2) vom Entkoppler-Gewindebolzen (1) abheben.

1 2

NOTE

Der Leistungsverbinder Plus ist in die ModulVerbindungsstecker gesteckt und kann ohne weiteres Werkzeug entnommen werden.

386_691-011

– Leistungsverbinder Plus (1) mit den Steckern (3) nach oben aus den Steckeranschlüssen (2) der Module ziehen.

Einbau – Persönliche Schutzausrüstung anziehen.

– Isoliertes Werkzeug verwenden.

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22

Battery group 2.2

Components BG 2.2 – Leistungsverbinder Plus (1) von oben mit den Steckern (3) in die Steckeranschlüsse (2) der Module stecken.

– Kontaktzunge Leistungsverbinder Plus (2) auf den Entkoppler-Gewindebolzen (1) stecken.

– Selbstsichernde Mutter M10 auf dem Entkoppler-Gewindebolzen (1) festschrauben.

1 2

Anzugsdrehmoment: 15 Nm

386_691-011

– CAN-Bus Kabel (1) in die zueinander liegenden Steckeranschlüsse (3) benachbarter Module stecken. Über die Steckeranschlüsse (2) weitere Nachbarmodule verbinden.

– Trogdeckel anbauen, siehe Abschnitt "Trogdeckel Abbau/Anbau".

– Betriebszustand wiederherstellen, siehe Abschnitt "Betriebszustand wiederherstellen".

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50988012057 EN - 12/2017

Battery group 2.2

22 Components BG 2.2

Temperature sensors

1 2

NTC 1 NTC 2

3 4

NTC 3 NTC 4

Batteriemodul Ausbau/Einbau DANGER Gefährliche elektrische Spannung!

Durch Berührung stromführender Bauteile kann es zu einem elektrischen Schlag kommen, der thermische oder muskellähmende Auswirkungen haben kann.

– Persönliche Schutzausrüstung anziehen.

– Isoliertes Werkzeug verwenden.

– Spannungsfreiheit herstellen.

Benötigte Spezialwerkzeuge: • Persönliche Schutzausrüstung • Aushebewerkzeug • Schraubenschlüssel SW 10 • Schraubendreher Torx (T10)

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22

Battery group 2.2

Components BG 2.2 Ausbau – Isolationswiderstand messen, siehe Abschnitt "Isolationswiderstand messen".

– Sicherstellen, dass die elektrische Anlage spannungsfrei ist, siehe Abschnitt "Spannungsfreiheit im Technikraum herstellen".

– Trogdeckel abbauen, siehe Abschnitt "Trogdeckel Abbau/Anbau".

– Leistungsverbinder Plus ausbauen, siehe Abschnitt "Leistungsverbinder Plus Ausbau/Einbau".

– Leistungsverteilerplatte (3) vom defekten Batteriemodul abnehmen.

– Sechskant-Sperrzahnschraube M6x567 (1) aherausschrauben.

– Niederhalter (2) abnehmen.

– Aushebewerkzeug anbauen.

WARNING Gefahr durch Heben schwerer Lasten!

Das Heben und Tragen von Hand ist nur bis zu einem Gewicht von max. 25 kg zulässig.

– Oberhalb 25 kg geeignete Hebezeuge oder Fördermittel verwenden.

Gerwicht Batteriemodul: ca. 30 kg – Hebezeug an das Batteriemodul bringen und am Aushebewerkzeug befestigen.

– Batteriemodul (1) senktrecht nach oben heben, bis das Batteriemodul frei über dem Batterietrog (2) hängt.

– Batteriemodul (1) vom Batterietrog (2) entfernen und standsicher abstellen.

– Hebezeug vom Aushebewerkzeug lösen.

– Aushebewerkzeug abbauen.

Einbau NOTE

Für den sicheren Rücktransport zum Batteriemodul-Hersteller ist nach dem Einbau eines neuen Batteriemoduls, das ausgebaute alte Batteriemodul in die verbliebene Batteriemodulverpackung des neues Batteriemoduls zu packen.

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50988012057 EN - 12/2017

Battery group 2.2

22 Components BG 2.2

– Aushebewerkzeug anbauen.

– Hebezeug an das Batteriemodul bringen und am Aushebewerkzeug befestigen.

WARNING Gefahr durch Heben schwerer Lasten!

Das Heben und Tragen von Hand ist nur bis zu einem Gewicht von max. 25 kg zulässig.

– Oberhalb 25 kg geeignete Hebezeuge oder Fördermittel verwenden.

Gerwicht Batteriemodul: ca. 30 kg – Batteriemodul zum Batterietrog bringen und anheben, bis das Batteriemodul senkrecht und frei über dem Batterietrog hängt.

NOTE

Die Steckeranschlüsse des Leistungsverbinders Plus auf der Oberseite und des Leistungsverbinders Minus auf der Unterseite des Batteriemoduls sind deckungsgleich. Beim Einbau des Batteriemoduls muss der Steckeranschluss für den Leistungsverbinder Plus senkrecht über dem Stecker des Leistungsverbinders Minus im Trog zu sehen sein.

Die Zentrierbolzen (3) im Batterietrog sorgen für ein passgenaues Einrasten des Steckers Leistungsverbinder Minus (4) in den Steckeranschluss auf der Batteriemodulunterseite.

Die Zentrierbohrungen (2) auf der Batteriemodulunterseite sorgen für ein passgenaues Einrasten des Steckeranschlusses Leistungsverbinder Minus (1) in den Stecker im Batterietrog.

– Prüfen, in welcher Stellung der entsprechende Stecker des Leistungsverbinders Minus und die Zentrierbolzen im Batterietrog zu sehen sind.

– Batteriemodul mit dem Steckeranschluss Leistungsverbinders Plus und den Zentriebbohrungen über der Einbauposition ausrichten.

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22

Battery group 2.2

Components BG 2.2 – Vorsichtig das Batteriemodul (1) senktrecht in den Trog (2) absenken, bis dieses fest auf dem Trogboden steht.

– Prüfen, ob das Batteriemodul sicher eingerastet und in der Einbauposition zentriert ist.

– Hebezeug vom Aushebewerkzeug lösen und von der Batterie entfernen.

– Aushebewerkzeug abbauen.

– Sechskant-Sperrzahnschraube M6x567 (1) mit Niederhalter (2) einschrauben und über vier zueinander stehenden Batteriemodulen ausrichten.

– Sechskant-Sperrzahnschraube (1) festschrauben.

Anzugsdrehmoment: 6 Nm – Leistungsverteilerplatte (3) auf das Batteriemodul legen.

– Leistungsverbinder Plus einbauen, siehe Abschnitt "Leistungsverbinder Plus Ausbau/Einbau".

– Trogdeckel anbauen, siehe Abschnitt "Trogdeckel Abbau/Anbau".

– Betriebszustand wiederherstellen, siehe Abschnitt "Betriebszustand wiederherstellen".

– Wurde ein defektes Batteriemodul ausgetauscht, das defekte Batteriemodul in die Batteriemodulverpackung einpacken.

CAN bus terminating resistor (120 Ω) The CAN bus is equipped with a terminating resistor (120 Ω). The terminating resistor is plugged into the last plug connector on the CAN bus. Uninterrupted operation cannot be guaranteed without a terminating resistor.

– Pull the terminating resistor (1) out from the plug connection on the removed module.

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50988012057 EN - 12/2017

Battery group 2.2

22 Components BG 2.2

– Place the terminating resistor (1) at the cable end of the CAN bus into the plug connection on the new module.

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22

Battery group 2.2

Technology compartment BG 2.2 Technikraum öffnen/schließen Benötigte Spezialwerkzeuge: • Innensechskantschlüssel SW 5

Öffnen – Isolationswiderstand messen, siehe Abschnitt "Isolationswiderstand messen".

– Zylinderschrauben M6x10 (1) herausschrauben.

WARNING Gefahr durch Heben schwerer Lasten!

Das Heben und Tragen von Hand ist nur bis zu einem Gewicht von max. 25 kg zulässig.

– Oberhalb 25 kg geeignete Hebezeuge oder Fördermittel verwenden.

– Servicedeckel (2) abbauen.

Gewicht: 17 kg

Schließen Vor dem Anbauen des Servicedeckels sichterstellen: • Die Deckeldichtung in der Batterietrogwand ist einwandfrei und sitzt korrekt in der Dichtungsnut.

• Die Dichtfläche des Servicedeckels ist sauber und unbeschädigt.

WARNING Gefahr durch Heben schwerer Lasten!

Das Heben und Tragen von Hand ist nur bis zu einem Gewicht von max. 25 kg zulässig.

– Oberhalb 25 kg geeignete Hebezeuge oder Fördermittel verwenden.

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Battery group 2.2

22 Technology compartment BG 2.2

– Servicedeckel (2) vor den Technikraum stellen.

Gewicht: 17 kg – Sicherstellen, dass sich keine Kabel zwischen Servicedeckel (2) und Anschraubfläche befinden.

– Servicedeckel anbauen.

– Zylinderschrauben M6x10 (1) festschrauben.

Anzugsdrehmoment: 9 Nm – Isolationswiderstand messen, siehe Abschnitt "Isolationswiderstand messen".

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Battery group 2.2

Technology compartment BG 2.2 Current/voltage sensor (CVS) The CVS measures the current and voltage and supports the BMS in evaluating the power requirements of the truck.

Tasks in detail: • Measuring the battery current (Messshunt) • Measuring the battery voltage • Temperature measurement Messshunt • Galvanic isolation of 48 V control voltage supply • Measured value transmission to BMC via CAN Voltage measurements: • Measurement of voltage + modules directly after 450 A fuse (S1-) • Measurement of voltage after connected contactor K1 (K1+)

1 2 X71 X72

Battery module connection Battery male connector connection Connection BMC Voltage measurement

• Measurement of output voltage after connected contactor K2 (K2-)

Removing/installing the current/voltage sensor DANGER Dangerous electrical voltage!

Touching live components can lead to an electric shock, which can have thermal or paralysing effects.

– Wear personal protective equipment.

– Use insulated tools.

– De-energise the system.

Special tools required: • AF 10 spanner

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Battery group 2.2

22 Technology compartment BG 2.2

Removal – De-energise the technology compartment; see the section entitled "De-energising the technology compartment".

– Disconnect the plugs X71 (2) and X72 (1).

– Remove the protective caps and unscrew the M6x20 hexagon head screws (1).

– Unscrew the M6x20 hexagon head screws (2) and remove the BCM/CVS connecting cable.

– Pull out the current/voltage sensor (2) from under the conductor rails (1) and remove it.

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Battery group 2.2

Technology compartment BG 2.2 Removing the support for the current/voltage sensor – Unscrew the M6 nut (1).

– Remove the support for the current/voltage sensor (2).

Installing – Insert the support for the current/voltage sensor (2).

– Tighten the M6 nut (1).

Install the current/voltage sensor – Slide the current/voltage sensor (2) under the conductor rails (1).

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22 Technology compartment BG 2.2

– Fit the BCM/CVS connecting cable on the M6x20 hexagon head screw (2) and tighten it.

– Fit and tighten the M6x20 hexagon head screws(1).

Tightening torque: 9 Nm – Attach the protective caps (1).

– Connect the plugs X71 (2) and X72 (1).

– Restore operating status; see the section entitled "Restoring operating status".

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22

Battery group 2.2

Technology compartment BG 2.2 Brake chopper module (BCM) Functional description The BCM monitors battery voltage during truck operation. If the battery voltage exceeds the value of 53.9 V in a 48 V lithium-ion system due to recuperation, the system is automatically activated.

It connects a resistor in parallel with the battery using power electronics. The resistor absorbs the average regenerative power, which keeps the battery voltage constant at approximately 53.7 V. The housing of the BCM includes three LEDs. These indicate the current status of the component independently of the BMC.

1 2 3 4 5 6 7

Connection R+ on brake resistor (+) Connection R- on brake resistor (-) X42 (2-pin) connection on brake resistor NTC temperature sensor BAT- connection X41 (6-pin) connection on brake resistor BMC Status LED BAT+ connection

Status LED

1 2 3

LED

on/off

BCM operating mode

All

Off

Switched off

"enable"

On

Ready

"ready"

On

Active

"ready"

Off

Active - is then switched off

"pre-charge"

On

Pre-charging active

22-34

"enable" LED (enabled by master) "ready" LED (temperature monitoring/performance) "pre-charge" LED

Function Release available, must be performed by the BMC Temperature monitoring of the NTC resistance on the brake resistor within the specified temperature range Temperature monitoring of the NTC resistance on the brake resistor outside the specified temperature range Internal pre-charging of the BCM pre-charge relay by the BMC (must be charged for 200 ms before the main contactors close)

50988012057 EN - 12/2017

Battery group 2.2

22 Technology compartment BG 2.2

Enabled by master The "enable" LED (1) indicates the enable status signalled by the BMC. If the LED is illuminated, the enable signal is present.

The BMC can disable the BCM component depending on the truck condition/battery status.

Temperature monitoring/performance The BCM monitors the temperature of the power electronics internally and monitors the temperature of the brake resistor externally with an additional open circuit detector. The two temperature monitors are standardised into a single "performance" parameter. This is transmitted to the BMC via pulse width modulation using PIN "feedback" and indicated by the "ready" LED (2). The pulse width modulation frequency is approx. 10 Hz. The LED is illuminated constantly when the component is performing at 100%. If the LED flashes briefly, this indicates increased performance. If the LED flashes slowly, this indicates decreased performance. If performance is at 0% or if there is a cable break in the external temperature sensor, the LED is off.

Pre-charging The BCM has an internal pre-charge circuit for the intermediate circuit of the BCM. Precharging is controlled by the BMC. The status of the pre-charge path is indicated by the "pre-charge" LED (3). If the LED lights up, pre-charging is active.

Status description There are three internal testing and measurement circuits that function independently of each other. All measurement, detection and control is analogue (performed without software): • Continuous testing for line breakage of the external temperature sensor • Continuous measurement of the performance electronics temperature and the brake resistor as well as adaptation of the feedback signal • Testing the battery voltage and generating switching signals for the power transistors

BCM self-protection The BMC uses the feedback signal from the BCM to adjust the maximum permissible recuperated power to keep the BCM system within the permissible temperature range. If the truck does not adhere to this value, the BCM system switches off automatically to protect itself.

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22

Battery group 2.2

Technology compartment BG 2.2 Removing/installing the brake chopper module DANGER Dangerous electrical voltage!

Touching live components can lead to an electric shock, which can have thermal or paralysing effects.

– Wear personal protective equipment.

– Use insulated tools.

– De-energise the system.

Special tools required: • Hexagon socket wrench AF 3 • Hexagon socket wrench AF 8 • Hexagon socket key AF 10

Removing

4

3

2

1

11 12

3

4

NOTE

The BCM (1) must be removed together with the carrier plate (2). Otherwise, not all of the screw connections that connect the BCM to the mounting plate will be accessible.

• The tensioning stabiliser (3) behind the con-

nectors for the brake resistor (5) is accessible only once the brake resistor has been removed

– Ensure that the electrical system is de-energised; see the section entitled "De-energising the technology compartment".

– Disconnect the NTC temperature sensor at the X42 connector (9).

10

9

– Remove the brake resistor; see the section entitled "Removing/installing the brake resistor".

– Disconnect the BMC signal plug at the X41 connector (12).

– Unscrew the socket head screw (6) at the BAT+ connection.

– Remove the BAT+ (7) cable from the BCN. – Unscrew the M10x12 (8) socket head screw.

– Remove the BCM/CVS cable (10) from the BCM. – Unscrew the M6 flanged nuts (4).

– Remove the tensioning stabilisers (3) – Remove the BCM (1) together with the carrier plate (2).

– Unscrew the M4x10 socket head screws (11).

– Remove the BCM from the carrier plate.

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8

7

6

5

386_609-029

Battery group 2.2

22 Technology compartment BG 2.2

Installing – Ensure that the electrical system is de-energised; see the section entitled "De-energising the technology compartment".

4

3

2

1

11 12

3

4

– Place the BCM (1) on the carrier plate (2).

– Tighten the M4x10 socket head screws (11).

Tightening torque: 2.5 Nm – Insert BCM together with the carrier plate.

– Fit the tensioning stabilisers (3) .

– Tighten the M6 flanged nuts (4).

Tightening torque: 9 Nm – Place the BCM/CVS cable (10) on the BATconnector.

10

9

8

7

6

5

386_609-029

– Tighten the M10x12 socket head screw (8).

Tightening torque: 15 Nm – Place the BAT+ cable (7) on the BAT+ connector.

– Tighten the socket head screw (6).

Tightening torque: 2.5 Nm – Connect the BMC signal plug to the X41 connector (12).

NOTE

When the brake resistor is being installed, the right-hand tensioning stabiliser is covered by the brake resistor connector (5). Before installing the brake resistor, make sure the flanged nuts (4) are fully tightened.

– Install the brake resistor; see the section entitled "Removing/installing the brake resistor".

– Connect the NTC temperature sensor to the X42 connector (9).

– Restore operating status; see the section entitled "Restoring operating status".

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Battery group 2.2

Technology compartment BG 2.2 Brake resistor 105 mΩ

1

WARNING Danger of burns from the hot brake resistor!

The temperature of the brake resistor can rise to >100 °C during operation. It can take several hours for the brake resistor to cool down to a low hazard temperature. Thermal radiation can also affect other components in and around the technical compartment, which then become hot.

– Do not touch hot surfaces with bare hands.

– Wear protective gloves.

The brake resistor is used to absorb recovered energy (braking energy) if the brake current exceeds the generator voltage of the traction motor.

The NTC resistor monitors the temperature and provides feedback to the brake chopper module.

Technical data Resistance value Resistance value tolerance Insulation resistance Operating voltage

105 mΩ

>50 MΩ UMAX = 54 V (48 V)

Nominal voltage

Unominal = 13 x 3.75 V

Final charged voltage

13 x 4.12 V

4

1 2 3 4

Brake resistor 105 mΩ Connection to BCM "R-" Connection to BCM "R+" Connection to contactor connectors "K1"/"K2"

±10%

10 kΩ 503 mm / 100 mm / 50 mm

.

Removing/installing the brake resistor DANGER Dangerous electrical voltage!

Touching live components can lead to an electric shock, which can have thermal or paralysing effects.

– Wear personal protective equipment.

– Use insulated tools.

– De-energise the system.

22-38

2 386_609-001

Test voltage (1 minute) UP = 1200 V DC NTC resistance Dimensions (length / width / height)

3

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22 Technology compartment BG 2.2

WARNING Danger of burns from the hot brake resistor!

During operation, the brake resistor temperature can rise to >100°C. It can take several hours for the brake resistor to cool down to a low hazard temperature.

Thermal radiation can also affect other components in and around the technical compartment, which then heat up.

– Do not touch hot surfaces with bare hands.

– Wear protective gloves.

Special tools required: • Hexagon socket wrench AF 6 • Hexagon socket wrench AF 8

Removal – Ensure that the electrical system is de-energised; see the section entitled "De-energising the technology compartment".

– Remove the tray cover; see the section entitled "Removing/fitting the tray cover".

– Remove the positive power connector; see the section entitled "Removing/installing the positive power connector".

– Unscrew the M10x12 socket head screws (2) and (4) on the BMC (5).

The connectors (1) and (3) remain on the brake resistor.

– Pull out the NTC plug (6).

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Battery group 2.2

Technology compartment BG 2.2 – Remove the protective cap from the M10 flanged nut (1) on the contactor bridge (4).

– Unscrew M10 flanged nut (1).

– Remove the ring terminal (3) from the M10 threaded bolt (2).

– Unscrew the M8x35 socket head screw (2) along with the lock washer.

– Remove the retaining key (1).

– Lift the brake resistor (3) and remove it.

Installation – Insert the brake resistor (1) from above.

– Ensure that the brake resistor slides into the lower latch (2).

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22 Technology compartment BG 2.2

– Fit the retaining key (1) at the top of the brake resistor (3).

– Screw on the M8x35 socket head screw (2) along with the lock washer.

Tightening torque: 12 Nm

– Insert the ring terminal (3) on the M10 threaded bolt (2) of the contactor bridge(4).

– Tighten the M10 flanged nut (1).

Tightening torque: 15 Nm – Place a protective cap on the flanged nut (1).

– Fit the brake resistor connector (1, 3) on the BMC (5).

– Screw the M10x12 socket head screws (2, 4) along with the lock washer onto the BMC. Tightening torque: 15 Nm – Attach the NTC plug (6).

– Install the positive power connector; see the section entitled "Removing/installing the positive power connector".

– Fit the tray cover; see the section entitled "Removing/fitting the tray cover".

– Restore operating status; see the section entitled "Restoring operating status".

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22

Battery group 2.2

Technology compartment BG 2.2 Battery master controller (BMC) The BMC determines the charge and overall condition of all the battery cells. It communicates with the industrial truck via the CAN bus and with the CSC via the internal CAN bus.

Tasks in detail: • Activation of the main contactors, K1 and K2 • Monitoring of the battery modules • Safety monitoring function of the battery modules • Communication with the truck control unit • Communication with the battery display and the shock sensor • Communication with the BCM

1 2 3 X11 X12 X13 X14

LEDs (x2), BMC main processor BMC LEDs (2 pieces) BMC monitoring computer Diagnostics, CAN, contactors, BCM, SSV CSC Battery display / shock sensor Power supply

LED codes BMC LEDs Off Flashing white

Computer BMC Main processor and monitoring processor Main processor and monitoring processor

Flashing white + blue

Main processor

Solid white + blue

Main processor

Solid blue

Monitoring processor

Flashes blue once

Monitoring processor

.

Removing/installing the battery master controller DANGER Dangerous electrical voltage!

Touching live components can lead to an electric shock, which can have thermal or paralysing effects.

– Wear personal protective equipment.

– Use insulated tools.

– De-energise the system.

Special tools required: • Spanner AF 10

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50988012057 EN - 12/2017

Operating status Quiescent state Ready, charging or driving Self testing, emergency operation, error with error analysis Malfunction (with error, including up to shut-off 1) Feedback signal deactivated Normal operation, feedback signal test

Battery group 2.2

22 Technology compartment BG 2.2

Removal – De-energise the technology compartment; see the section entitled "De-energising the technology compartment".

– Disconnect plugs X11 (5), X12 (4), X13 (3) and X14 (6).

– Unscrew ratchet screws M6x16 (1).

– Remove the battery master controller (2) together with the carrier plate.

Installing – Fit the battery master controller (2) together with the carrier plate.

– Tighten ratchet screws M6x16 (1).

Tightening torque: 9 Nm – Connect plugs X11 (5), X12 (4), X13 (3) and X14 (6).

– Restore operating status; see the section entitled "Restoring operating status".

50988012057 EN - 12/2017

22-43

22

Battery group 2.2

Technology compartment BG 2.2 Control voltage supply (SSV) with reset button The SSV supplies the truck electrics with power before the battery is switched on and ensures a continuous power supply to the DC/DC converter.

1 2

3

X51 - pin assignment: X52

• PIN 1

X51

Blocking signal from BMC • PIN 2 Negative X52 - pin assignment: • PIN 1 Negative connection

386_609-122

• PIN 2 Battery positive connection before switch-on contactor • PIN 3

1 2 3

Plug connector X51 Reset button Plug connector X52

Control voltage to truck • PIN 4 Battery positive connection to battery voltage transformer Tasks in detail: • Supplies the truck electrics with power before the battery is switched on • Switches the power supply off after the battery is switched off • Switches off the battery supply voltage in the event of under voltage • Switches off the battery supply voltage from BMC • Switches off the complete power supply • Limits the control current to the truck • Prevents battery charging from the control voltage (voltage feedback protection)

Removing/installing the control voltage supply unit DANGER Dangerous electrical voltage!

Touching live components can lead to an electric shock, which can have thermal or paralysing effects.

– Wear personal protective equipment.

– Use insulated tools.

– De-energise the system.

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50988012057 EN - 12/2017

Battery group 2.2

22 Technology compartment BG 2.2

Special tools required: • AF 10 spanner

Removal – De-energise the technology compartment; see the section entitled "De-energising the technology compartment".

– Remove the battery master controller; see the section entitled "Removing/installing the battery master controller".

– Disconnect the plug X51 (2) and the plug X52 (1).

– Unscrew the M6 flanged nuts (3).

– Remove the SSV.

Installing – Insert the SSV. – Tighten the M6 flanged nuts (3).

– Tightening torque: 9 Nm – Connect plug X51 (1) and plug X52 (2).

– Install the battery master controller; see the section entitled "Removing/installing the battery master controller".

– Restore operating status; see the section entitled "Restoring operating status".

50988012057 EN - 12/2017

22-45

22

Battery group 2.2

Technology compartment BG 2.2 Contactor assembly When commissioning the truck, the contactors are enabled as long as the battery is ready for operation.

1 2 3

Contactor K1 Connector plug X94 Contactor K2

Removing/installing the contactor assembly DANGER Dangerous electrical voltage!

Touching live components can lead to an electric shock, which can have thermal or paralysing effects.

– Wear personal protective equipment.

– Use insulated tools.

– De-energise the system.

Special tools required: • Spanner AF 10 • Spanner AF 15

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50988012057 EN - 12/2017

Battery group 2.2

22 Technology compartment BG 2.2

Removal – Ensure that the electrical system is de-energised; see the section entitled "De-energising the technology compartment".

– Remove the protective cap (1).

– Disconnect the plug X14 (3).

– Disconnect the plug X94 (2).

Remove the connector between contactor K1/contactor K2.

– Unscrew M10 flanged nut (2).

– Remove the connector between the brake resistor/contactor bridge (3) from the threaded bolt (1).

– Unscrew M10 flanged nut (5).

– Remove the connector between contactor K1/contactor K2 (8) from the threaded bolt (4) .

The electrical connection between contactor K1 (6) and contactor K2 (7) is now broken.

Remove the connector between contactor K1/positive main power connection.

– Unscrew M10 flanged nut (5).

– Unscrew M10x20 hexagon head screw (3).

– Remove the connector between contactor K1/positive main power connection (4) from the threaded bolt (6).

The electrical connection between contactor K1 (1) and positive main power connection (2) is now broken.

50988012057 EN - 12/2017

22-47

22

Battery group 2.2

Technology compartment BG 2.2 Remove the connector between contactor K2/positive main power connection.

– Unscrew M10 flanged nut (1).

– Unscrew M10x20 hexagon head screw (3).

– Remove the connector between contactor K2/positive main power connection (2).

The electrical connection between contactor K2 (6) and positive main power connection (5) is now broken.

Remove the contactor bridge.

– Unscrew M6x16 hexagon head screw (3).

– Remove cable tie (4).

– Unscrew M6 long nut (5).

– Unscrew M6 hexagon nut (2).

– Remove the contactor bridge (1) with contactors.

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50988012057 EN - 12/2017

Battery group 2.2

22 Technology compartment BG 2.2

Remove contactor K1 and K2.

– Unscrew M6 flanged nut (2).

– Remove contactor K1 (3) and contactor K2 (4) from the contactor bridge (1).

Installing

Attach contactor K1 and K2.

– Connect contactor K1 (3) and contactor K2 (4) to the contactor bridge (1).

– Tighten the M6 flanged nut (2).

Tightening torque: 9 Nm

Install contactor bridge.

– Place the contactor bridge (1) on the rear wall of the technical compartment.

– Tighten the M6 hexagon nut (2).

Tightening torque: 9 Nm – Tighten the M6 long nut (5).

Tightening torque: 9 Nm – Tighten the M6x16 hexagon head screw (3) with cable ties (4).

Tightening torque: 9 Nm

50988012057 EN - 12/2017

22-49

22

Battery group 2.2

Technology compartment BG 2.2 Install the connector between contactor K2/positive main power connection.

– Fit the connector between contactor K2 /positive main power connection (3)onto the threaded bolt (2) at the contactor K2 (6).

– Align the connector between contactor K2 /positive main power connection with the threaded hole on the positive main power connection (5).

– Tighten the M10x20 hexagon head screw (4).

Tightening torque: 15 Nm – Tighten the M10 flanged nut (1).

Tightening torque: 15 Nm

Install the connector between contactor K1/positive main power connection.

– Fit the connector between contactor K1 /positive main power connection (4)onto the threaded bolt (6) at the contactor K1 (1).

– Align the connector between contactor K1 /positive main power connection with the threaded hole on the positive main power connection (2).

– Tighten the M10x20 hexagon head screw (3).

Tightening torque: 15 Nm – Tighten the M10 flanged nut (5).

Tightening torque: 15 Nm

Install the connector between contactor K1/contactor K2 – Fit the connector between contactor K1/contactor K2 (8) onto the threaded bolt (4) above contactor K1 (6) and contactor K2 (7).

– Tighten the M10 flanged nut (5).

Tightening torque: 15 Nm – Fit the brake resistor/contactor bridge (3) onto the threaded bolt (1) on the connector between contactor K1/contactor K2.

– Tighten the M10 flanged nut (2).

Tightening torque: 15 Nm

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50988012057 EN - 12/2017

Battery group 2.2

22 Technology compartment BG 2.2

– Attach plug X94 (2).

– Attach plug X14 (3).

– Attach the protective cap (1).

– Restore operating status; see the section entitled "Restoring operating status".

50988012057 EN - 12/2017

22-51

22

Battery group 2.2

Technology compartment BG 2.2 Voltage transformer (DC/DC) The DC/DC voltage transformer ensures a permanent power supply to the BMC and the diagnostic interface.

• Input voltage 48 V from SSV • 12 V output voltage • Supply from: BMC CSC CVS Battery display / shock sensor

1 2

DC/DC voltage transformer Plug connection

Removing/installing the voltage transformer DANGER Dangerous electrical voltage!

Touching live components can lead to an electric shock, which can have thermal or paralysing effects.

– Wear personal protective equipment.

– Use insulated tools.

– De-energise the system.

Special tools required: • Hexagon socket wrench AF 4 • AF 10 spanner

Removal – Ensure that the electrical system is de-energised; see the section entitled "De-energising the technology compartment".

– Remove the tray cover; see the section entitled "Removing/fitting the tray cover".

– Remove the positive power connector; see the section entitled "Removing/installing the positive power connector".

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50988012057 EN - 12/2017

Battery group 2.2

22 Technology compartment BG 2.2

– Disconnect the connector plug (4) from the voltage transformer.

– Unscrew the M6 flanged nut (2).

– Unscrew the M5x10 countersunk screw (5).

– Slide the upper cradle (1) off the clamping sleeve (6) and the threaded bolt (3), and remove the upper cradle.

– Pull the voltage transformer (1) with the base plate (3) upwards and remove it.

– If necessary, remove the clamping sleeve (2).

The voltage transformer and the base plate are loosely plugged into the recess (2) of the lower cradle (1).

– To remove the lower cradle (1), unscrew the flanged nut (3) and remove the lower cradle.

50988012057 EN - 12/2017

22-53

22

Battery group 2.2

Technology compartment BG 2.2 Installation – Ensure that the recess in the lower cradle (1) faces the wall of the technical compartment.

– Check the tightness of the M6 flanged nut (3).

Tightening torque: 5 Nm

– Push the voltage transformer (1) with the base plate (3) from above into the recess in the lower cradle.

– Ensure that the clamping sleeve (2) is present and is correctly installed.

– Push the upper cradle (1) onto the clamping sleeve (6) and threaded bolt (3).

– Tighten the M5x10 countersunk screw (5).

Tightening torque: 5 Nm – Tighten the M6 flanged nut (2).

Tightening torque: 9 Nm – Connect the connector plug (4).

– Install the positive power connector; see the section entitled "Removing/installing the positive power connector".

– Fit the tray cover; see the section entitled "Removing/fitting the tray cover".

– Restore operating status; see the section entitled "Restoring operating status".

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50988012057 EN - 12/2017

Battery group 2.2

22 Technology compartment BG 2.2

Electrical fuses Main fuse The main fuse on the positive power distribution side has a rating of 450 A.

1 F1

Fuse holder Main fuse (450 A)

1 F2 F3 F4 F5 F6

Fuse holder BMC / SSV (20 A) CVS voltage measurement S1- (3 A) CVS voltage measurement S2+ (3 A) CVS voltage measurement S2- (3 A) Pre-charging for the brake chopper (3 A)

Control current fuses The control current is protected by blade fuses in the fuse holder.

50988012057 EN - 12/2017

22-55

22

Battery group 2.2

Technology compartment BG 2.2 Blade fuses on the SSV

1

F20 386_609-015

1 F50

SSV Control units supply (20 A) power transmission path (output side)

Replacing electrical fuses DANGER Dangerous electrical voltage!

Touching live components can lead to an electric shock, which can have thermal or paralysing effects.

– Wear personal protective equipment.

– Use insulated tools.

– De-energise the system.

Special tools required: • Torque wrench AF 15 • Fuse puller for auto plug-in fuse

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50988012057 EN - 12/2017

Battery group 2.2

22 Technology compartment BG 2.2

Replacing the main fuse CAUTION Risk of damage to the contactors by triggering the main fuse.

Triggering the main fuse may cause "short-circuit current" that can damage the contactors.

– After the main fuse has been triggered, the contactors must be replaced.

– Ensure that the electrical system is de-energised; see the section entitled "De-energising the system".

1 F1

Fuse holder Main fuse (450 A)

– Remove protective caps (1).

– Unscrew ratchet screws M10x20 (2).

– Remove main fuse (3).

– Insert new main fuse with the same nominal current.

– Tighten ratchet screws M10x20 (2).

Tightening torque: 18 Nm – Attach the protective caps (1).

50988012057 EN - 12/2017

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22

Battery group 2.2

Technology compartment BG 2.2 Changing control current fuses Control current fuses in the fuse holder – Ensure that the electrical system is de-energised; see the section entitled "De-energising the system".

– Locate defective auto plug-in fuses (F2-F6) and remove from the fuse holder (1) using a fuse puller.

– Insert a new auto plug-in fuse with the same nominal current.

1 F2 F3 F4 F5 F6

Fuse holder BMC / SSV (20 A) CVS voltage measurement S1- (3 A) CVS voltage measurement S2+ (3 A) CVS voltage measurement S2- (3 A) Pre-charging of brake chopper (3 A)

Control current fuse on the SSV – Ensure that the electrical system is de-energised; see the section entitled "De-energising the system".

– Remove BMC. – Pull out the auto plug-in fuse (F20) using a fuse puller.

– Insert a new auto plug-in fuse with the same nominal current.

– Install BMC.

1

F20 386_609-015

1 F50

22-58

SSV Control units supply (20 A) power transmission path (output side)

50988012057 EN - 12/2017

Battery group 2.2

22

Wiring BG 2.2 Removing/installing the power cable DANGER Dangerous electrical voltage!

Touching live components can lead to an electric shock, which can have thermal or paralysing effects.

– Wear personal protective equipment.

– Use insulated tools.

Special tools required: • Hexagon socket wrench AF 5 • Spanner AF 22

Removing – Measure the insulation resistance; see the section entitled "Measuring the insulation resistance".

– Unscrew the M10x18 terminal bolt (1) from the positive power connection (6).

– Unscrew the M10x18 terminal bolt (4) from the negative power connection (5).

– Pull out the communication plug (7).

– Pull the positive power cable (2), the negative power cable (3) and the communication cable (7) upwards and out of the cable channel.

Installing – Pull the positive power cable (2), the negative power cable (3) and the communication cable (7) into the cable channel from above.

– Place the tab for the positive power cable (2) onto the M10x47 terminal bolt (1).

– Screw the M10x18 terminal bolt (1) along with the positive power cable (2) onto the positive power connection (6).

Tightening torque: 15 Nm – Place the tab for the negative power cable (3) onto the M10x47 terminal bolt (4).

– Screw the M10x18 terminal bolt (4) along with the negative power cable (3) onto the negative power connection (5).

Tightening torque: 15 Nm

50988012057 EN - 12/2017

22-59

22

Battery group 2.2

Wiring BG 2.2 – Insert the communication plug (7).

22-60

50988012057 EN - 12/2017

Index g A

Battery transport with crane . . . . . . . . . . . 00-6

Anode . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-8

B

BCM . . . . . . . . . . . . . . . . . . . . . 21-38, 22-34 Betriebszustand wiederherstellen . . . . . . . 22-8 Flachstecksicherung F2 einsetzen . . 22-10 Hauptsicherung einbauen . . . . . . . . . 22-9

Batterie-Display

Spezialwerkzeuge . . . . . . . . . . . . . . . 22-8

Ausbau . . . . . . . . . . . . . . . . . . . . . . 22-14 Einbau . . . . . . . . . . . . . . . . . . . . . . . 22-16 Batteriemodul 2.2

Technikraum schließen . . . . . . . . . . 22-10 Brake chopper module . . . . . . . . 21-38, 22-34 Functional description . . . . . 21-38, 22-34

Ausbau . . . . . . . . . . . . . . . . . . . . . . 22-24

Installing . . . . . . . . . . . . . . . 21-41, 22-37

Einbau . . . . . . . . . . . . . . . . . . . . . . . 22-24

Removing . . . . . . . . . . . . . . 21-40, 22-36

Battery cell

Self-protection . . . . . . . . . . . 21-39, 22-35

Structural principle . . . . . . . . . . . . . . . 00-8

Status description . . . . . . . . 21-39, 22-35

Battery display . . . . . . . . . 00-14, 21-15, 22-13 Charging state LEDs . 00-14, 21-15, 22-13 Installing . . . . . . . . . . . . . . . . . . . . . 21-17

Status LED . . . . . . . . . . . . . 21-38, 22-34 Brake resistor 105 mΩ . . . . . . . . . . . . . . . . 21-43, 22-38

Removing . . . . . . . . . . . . . . . . . . . . 21-16

Installation . . . . . . . . . . . . . . . . . . . . 22-40

Service LED . . . . . . . . 00-15, 21-15, 22-13

Installing . . . . . . . . . . . . . . . . . . . . . 21-45

Temperature LED . . . 00-15, 21-15, 22-13

Removal . . . . . . . . . . . . . . . . . . . . . 22-38

Battery group 1.1

Removing . . . . . . . . . . . . . . . . . . . . 21-43

Technical compartment . . . . . . . . . . . 22-4 Battery group 1.2 Technical compartment . . . . . . . . . . . 22-4 Battery group 12.1 Design . . . . . . . . . . . . . . . . . . . . . . . . 21-3 Battery group 2.1 Technology compartment . . . . . . . . . . 21-4 Tray cover . . . . . . . . . . . . . . . . . . . . 21-13 Battery group 2.2 Design . . . . . . . . . . . . . . . . . . . . . . . . 22-2 Tray cover . . . . . . . . . . . . . . . . . . . . 22-11 Battery master controller . . . . . . 21-46, 22-42 Installing . . . . . . . . . . . . . . . . . . . . . 22-43 Removal . . . . . . . . . . . . . . . . . . . . . 22-43 Tasks . . . . . . . . . . . . . . . . . 21-46, 22-42 Battery master controller 2.1

C Cathode . . . . . . . . . . . . . . . . . . . . . . . . . 00-8 Charging Operating principle . . . . . . . . . . . . . . . 00-8 Cleaning the battery . . . . . . . . . . . . . . . . . 01-1 Connector between contactor K1/contactor K2 Installing . . . . . . . . . . . . . . . 21-54, 22-50 Removing . . . . . . . . . . . . . . 21-51, 22-47 Connector between contactor K1/main positive connection Installing . . . . . . . . . . . . . . . . . . . . . 21-54 Removing . . . . . . . . . . . . . . . . . . . . 21-51 Connector between contactor K1/positive main power connection

Installing . . . . . . . . . . . . . . . . . . . . . 21-47

Installing . . . . . . . . . . . . . . . . . . . . . 22-50

Removing . . . . . . . . . . . . . . . . . . . . 21-47

Removing . . . . . . . . . . . . . . . . . . . . 22-47

Battery module Exploded view . . . . . . . . . . . . . . . . . 00-12 Installing . . . . . . . . . . . . . . . . . . . . . 21-30 Main components . . . . . . . . . . . . . . . 00-11 Removing . . . . . . . . . . . . . . . . . . . . 21-30 Structural principle . . . . . . . . . . . . . . 00-10 Battery size 2.1 De-energising the technology compartment . . . . . . . . . . . . . . . . 21-6

Connector between contactor K2/main positive connection Installing . . . . . . . . . . . . . . . . . . . . . 21-54 Removing . . . . . . . . . . . . . . . . . . . . 21-52 Connector between contactor K2/positive main power connection Installing . . . . . . . . . . . . . . . . . . . . . 22-50 Removing . . . . . . . . . . . . . . . . . . . . 22-48

50988012057 EN - 12/2017

1

Index g Contactor assembly . . . . . . . . . . 21-50, 22-46

CVS

Installing . . . . . . . . . . . . . . . 21-53, 22-49 Removal . . . . . . . . . . . . . . . . . . . . . 22-47

Securing the conductor rails . . . . . . . 21-36 CVS support

Removing . . . . . . . . . . . . . . . . . . . . 21-51

Installing . . . . . . . . . . . . . . . . . . . . . 21-37

Contactor bridge

Removing . . . . . . . . . . . . . . . . . . . . 21-36

Installing . . . . . . . . . . . . . . . 21-53, 22-49 Removing . . . . . . . . . . . . . . 21-52, 22-48

D Dangerous misuse . . . . . . . . . . . . . . . . . . 00-4

Contactor K1 Attaching . . . . . . . . . . . . . . . . . . . . . 22-49

De-energised technology compartment Checking . . . . . . . . . . . . . . . . . . . . . . 21-9

Fitting . . . . . . . . . . . . . . . . . . . . . . . 21-53 Removing . . . . . . . . . . . . . . 21-53, 22-49 Contactor K2

De-energising the technology compartment Battery size 2.1 . . . . . . . . . . . . . . . . . 21-6

Attaching . . . . . . . . . . . . . . . . . . . . . 22-49

Opening the technology compartment . . . . . . . . . . . . . . . . . . . . . . 21-8

Fitting . . . . . . . . . . . . . . . . . . . . . . . 21-53 Removing . . . . . . . . . . . . . . 21-53, 22-49

Pulling out auto plug-in fuse F2 . . . . . . 21-7

Control current fuses

Removing the front module cover . . . . 21-6

Changing . . . . . . . . . . . . . . . . . . . . . 22-58

Removing the main fuse . . . . . . . . . . . 21-8

Replacing . . . . . . . . . . . . . . . . . . . . 21-61 Control voltage supply . . . . . . . . . . . . . . 21-48 Functions . . . . . . . . . . . . . . . 21-48, 22-44 Pin assignment . . . . . . . . . . 21-48, 22-44

Special tools . . . . . . . . . . . . . . . . . . . 21-6 Definition of terms . . . . . . . . . . . . . . . . . . . . V Design Battery group 2.1 . . . . . . . . . . . . . . . . 21-3

Removal . . . . . . . . . . . . . . . . . . . . . 22-45 Reset button . . . . . . . . . . . . . . . . . . 22-44 Control voltage supply unit Installing . . . . . . . . . . . . . . . . . . . . . 21-49

Battery group 2.2 . . . . . . . . . . . . . . . . 22-2 Diagnostic set-up 2.1 . . . . . . . . . . . . . . . . 21-2 Discharging Operating principle . . . . . . . . . . . . . . . 00-8

Removing . . . . . . . . . . . . . . . . . . . . 21-49 Control voltage supply unit 9.1 / 9.2 Installing . . . . . . . . . . . . . . . . . . . . . 22-45 Current/voltage sensor . . . . . . . . 21-35, 22-30 Functions . . . . . . . . . . . . . . . 21-35, 22-30 Installing . . . . . . . . . . 21-36 – 21-37, 22-32 Removal . . . . . . . . . . . . . . . . . . . . . 22-31 Removing . . . . . . . . . . . . . . . . . . . . 21-36 Voltage measurements . . . . 21-35, 22-30

E Electrical fuses . . . . . . . . . . . . . 21-58, 22-55 Changing control current fuses . . . . . 22-58 Control current fuses . . . . . . 21-58, 22-55 Main fuse . . . . . . . . . . . . . . . 21-58, 22-55 Replacing . . . . . . . . . . . . . . 21-59, 22-56 Replacing the control current fuses . . 21-61 Replacing the main fuse . . . . 21-60, 22-57 Electrolyte . . . . . . . . . . . . . . . . . . . . . . . . 00-8

2

50988012057 EN - 12/2017

Index g G

Lithium-ion battery Balancing . . . . . . . . . . . . . . . . . . . . 00-14

Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . V

First-aid measures . . . . . . . . . . . . . . . 00-5

Active materials . . . . . . . . . . . . . . . . . . . VI

LED display . . . . . . . . . . . . . . . . . . . 00-13

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . VI

Pressure compensation element . . . 21-20

Battery Management System . . . . . . . . . VI

Pressure equalising element . . . . . . 22-19

C-rate . . . . . . . . . . . . . . . . . . . . . . . . . . VI

Technological advantages . . . . . . . . . 00-9

Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . X

Temperature sensors . . . . . . 00-13, 22-23

Charging cycle . . . . . . . . . . . . . . . . . . . VII Electrodes . . . . . . . . . . . . . . . . . . . . . . . VI Energy density . . . . . . . . . . . . . . . . . . . . VI Final charged voltage . . . . . . . . . . . . . . VII Final discharged voltage . . . . . . . . . . . . VII Memory effect . . . . . . . . . . . . . . . . . . . VIII Nominal capacity . . . . . . . . . . . . . . . . . VIII Nominal energy . . . . . . . . . . . . . . . . . . VII

M Main fuse Replacing . . . . . . . . . . . . . . 21-60, 22-57 Measuring the insulation resistance Special tools . . . . . . . . . . . . . . 21-5, 22-5 Module holder Installing . . . . . . . . . . . . . . . . . . . . . 21-24

Nominal voltage . . . . . . . . . . . . . . . . . . VIII

Removing . . . . . . . . . . . . . . . . . . . . 21-22

Power source parallel connection . . . . . VIII Power source serial connection . . . . . . . IX Primary cell . . . . . . . . . . . . . . . . . . . . . . IX Rechargeable battery . . . . . . . . . . . . . . . V Recuperation . . . . . . . . . . . . . . . . . . . . . IX Regenerative braking . . . . . . . . . . . . . . . IX Secondary cell . . . . . . . . . . . . . . . . . . . . IX

I

N Nameplate of a lithium-ion battery . . . . . . . 00-1

O Operating principle Charging/discharging . . . . . . . . . . . . . 00-8

P

Insulation resistance Measuring . . . . . . . . . . . . . . . . 21-5, 22-5 Intended use . . . . . . . . . . . . . . . . . . . . . . 00-4

L

Pin assignment X51 . . . . . . . . . . . . . . . . . . . 21-48, 22-44 X52 . . . . . . . . . . . . . . . . . . . 21-48, 22-44 Positive power connector Installing . . . . . . . . . . . . . . . . . . . . . 21-28

Leistungsverbinder Plus Ausbau . . . . . . . . . . . . . . . . . . . . . . 22-20 Einbau . . . . . . . . . . . . . . . . . . . . . . . 22-21 Lifting tool Attaching . . . . . . . . . . . . . . . . . . . . . . 01-4 Removing . . . . . . . . . . . . . . . . . . . . . 01-4 List of abbreviations . . . . . . . . . . . . . . . . . . . III Lithium-ion batteries Nameplate . . . . . . . . . . . . . . . . . . . . . 00-1 Passive balancing . . . . . . . . . . . . . . 00-14

Removing . . . . . . . . . . . . . . . . . . . . 21-27 Power cable Installing . . . . . . . . . . . . . . . . . . . . . 21-62 Removing . . . . . . . . . . . . . . . . . . . . 21-62 Power cable 2.2 Installing . . . . . . . . . . . . . . . . . . . . . 22-59 Removing . . . . . . . . . . . . . . . . . . . . 22-59 Procedure in the event of a battery-related accident . . . . . . . . . . . . . . . . . . . . 00-5

Technical data 2.1 . . . . . . . . . . . . . . . 21-1 Technical data 2.2 . . . . . . . . . . . . . . . 22-1

50988012057 EN - 12/2017

3

Index g R

Technikraum 2.2 Öffnen . . . . . . . . . . . . . . . . . . . . . . . 22-28

Restoring operating status . . . . . . . . . . . . 21-9 Assembling the front module cover . . 21-12 Closing the technology compartment . . . . . . . . . . . . . . . . . . . . . 21-11 Inserting auto plug-in fuse F2 . . . . . . 21-11

Schließen . . . . . . . . . . . . . . . . . . . . 22-28 Technology compartment Battery group 2.1 . . . . . . . . . . . . . . . . 21-4 Technology compartment 2.1 Closing . . . . . . . . . . . . . . . . . . . . . . 21-33

Installing the main fuse . . . . . . . . . . . 21-10 Special tools . . . . . . . . . . . . . . . . . . 21-10

S

Opening . . . . . . . . . . . . . . . . . . . . . 21-33 Terminating resistor CAN bus . . . . . . . . . . . . . . . 21-32, 22-26

Schocksensor . . . . . . . . . . . . . . 21-19, 22-18

Transport directives . . . . . . . . . . . . . . . . . 00-6

Separator . . . . . . . . . . . . . . . . . . . . . . . . 00-8

Tray cover

Service plan . . . . . . . . . . . . . . . . . . . . . . . 01-1

Battery group 2.1 . . . . . . . . . . . . . . . 21-13

Spannungsfreiheit im Technikraum

Battery group 2.2 . . . . . . . . . . . . . . . 22-11

Prüfen . . . . . . . . . . . . . . . . . . . . . . . . 22-8

Tray lid 2.1 Fitting . . . . . . . . . . . . . . . . . . . . . . . 21-14

Spannungsfreiheit im Technikraum herstellen . . . . . . . . . . . . . . . . . . . 22-6 Flachstecksicherung F2 ziehen . . . . . 22-7

Removing . . . . . . . . . . . . . . . . . . . . 21-13 Trogdeckel 1.1 / 1.2

Hauptsicherung ausbauen . . . . . . . . . 22-7 Spezialwerkzeuge . . . . . . . . . . . . . . . 22-6

Anbau . . . . . . . . . . . . . . . . . . . . . . . 22-12 Trogdeckel 2.2

Technikraum öffnen . . . . . . . . . . . . . . 22-6 Special safety regulations . . . . . . . . . . . . . 00-2

Abbau . . . . . . . . . . . . . . . . . . . . . . . 22-11

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . 00-7

U

Support for the current/voltage sensor

Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V

Installing . . . . . . . . . . . . . . . . . . . . . 22-32 Removing . . . . . . . . . . . . . . . . . . . . 22-32

Voltage transformer . . . . . . . . . . 21-56, 22-52

T

Installation . . . . . . . . . . . . . . . . . . . . 22-54

Technical compartment

4

V

Installing . . . . . . . . . . . . . . . . . . . . . 21-57

Battery group 1.1 . . . . . . . . . . . . . . . . 22-4

Removal . . . . . . . . . . . . . . . . . . . . . 22-52

Battery group 1.2 . . . . . . . . . . . . . . . . 22-4

Removing . . . . . . . . . . . . . . . . . . . . 21-56

50988012057 EN - 12/2017

STILL GmbH 50988012057 EN – 12/2017