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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 I
Header
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List of abbreviations
NOTE
IV 50988012057 EN - 12/2017
Header
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Units
Glossary
Rechargeable battery
A rechargeable battery can store electrical en-
ergy by converting it into chemical energy and
then output this energy by reconverting it. This is
how all rechargeable cells or batteries work.
50988012057 EN - 12/2017 V
Header
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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 elec-
trically 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)
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.
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.
VI 50988012057 EN - 12/2017
Header
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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
.
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.
Nominal energy
The nominal energy (Wh) is the energy in watt-
hours that a battery can output under defined
conditions.
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.
386_000-001
Primary cell
Primary cells (1) are not rechargeable and can be
discharged only once.
386_000-002
Secondary cell
Secondary cells are rechargeable.
50988012057 EN - 12/2017 IX
Header
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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)
X 50988012057 EN - 12/2017
Table of contents
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00 Product information
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-1
Overview of the battery groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-1
Nameplate of a lithium-ion battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-1
01 Service
Maintenance and repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
Cleaning the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
50988012057 EN - 12/2017 XI
Table of contents
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Foreword
Overview of the battery groups
Available Tray dimensions [mm]
Truck energy Circuit Tray no.
Capacity Length Width Height
Battery group 2
13.1 kWh
2.1 1030 529 350
268 Ah
RX20 14-20 48 V B 315
48.9 kWh
2.2 1030 529 627
1005 Ah
.
Safety information
Special safety regulations
Special safety regulations must be observed Special safety instructions
for lithium-ion batteries. An industrial truck with
lithium-ion-battery must be identified accordingly DANGER
with a lithium-ion label. Risk of explosion!
All lithium-ion batteries are essentially associated External temperatures of >80 °C can cause the battery
with the risk of a fire starting, of the battery to explode.
exploding and of the battery causing chemical – Never heat the battery to over 80 °C or expose it to
naked flames.
burns. The escape of dangerous substances
from the enclosed battery tray can be excluded
only by correct use and safe handling. The risk DANGER
of contact with toxic or corrosive substances
exists only in cases of improper handling leading Risk of injury!
to safety valves being opened or the housing The battery may be damaged or deformed in the event
being breached. These can result in electrolyte of an accident (impact, fall, collision). A strange smell,
an abnormal rise in temperature to >80°C, a change in
escaping, electrode materials reacting with
shape or any other anomaly may occur.
moisture and water, or fire and explosion.
– Establish a safety zone of five metres around the
The following guidelines must be observed: battery.
– Ensure sufficient ventilation.
– Observe the manufacturer’s information on
Linde lithium-ion technology. – If necessary, contact the emergency services
and inform them that there has been an accident
– Only work on the battery in areas that can be involving a lithium-ion battery.
easily ventilated in the event of an emergency.
– Use only the special tools, test equipment and
spare parts specified by the manufacturer. Other applicable standards and directives
– Only competent persons who have been DIN VDE 0100-410 voltage range I (for batteries
trained in how to work with Linde lithium-ion in battery groups 1 to 4)
technology may work on the batteries. DIN VDE 0105-100:2009-10
– Before carrying out any work on the battery,
put on personal protective equipment and NOTE
disconnect the battery.
Comply with the national laws and regulations of
– Never short-circuit the battery connectors.
the country in which the battery is used!
– Do not connect the battery with the polarity
reversed.
Personnel qualifications
– Do not subject the battery to excessive me-
chanical loads. According to the general principles for safe
operation, all persons involved in work with or
– Water can be used to cool down the incipient in the vicinity of electrical systems must be given
fire. instruction on the following subjects:
• Safety requirements
NOTE • Safety regulations
Before extinguishing fires, position yourself on • Operating instructions
the side of the fire from which the wind is blowing. Requirements for qualified personnel:
This will prevent inhalation of toxic fumes.
• Personnel must be approved according to
the current requirements of IEC 60449 or
DIN VDE 0100-410
• Observe instructions, regulations and require-
ments
• Wear suitable clothing for the work place
Intended use
The battery must be used only in accordance with Charge the battery using only the battery charger
the following documents: for lithium-ion batteries approved by the manu-
• The original operating instructions for the facturer.
industrial truck
NOTE
Use the battery only when it is in good working
order: If the charging state is less than 10%, charge the
• The battery must not be damaged and must battery as soon as possible. Leaving the cells
not indicate any errors discharged for several days negatively affects
• The cables to the battery charger must not be the service life of the battery.
damaged
• The cables to the industrial truck must not be NOTE
damaged.
When taking the battery out of operation for a
The battery must only be used in a suitable prolonged period (e.g. for company holidays),
industrial truck. The nominal voltage of the always ensure the battery is charged (50% -
battery must correspond to the operating voltage 100%).
of the industrial truck (see "Technical data").
Dangerous misuse
DANGER DANGER
Improper handling can lead to an The penetration of water can cause short circuit and
explosion or cause a fire! fire!
– Never use the battery in areas where – Prevent liquids from penetrating the battery.
there is a risk of fire or a risk of
explosion.
– Never heat the battery to over 80°C or DANGER
expose it to an open flame.
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 manu-
facturer's instructions.
– Do not improperly dismantle the battery.
– Do not disassemble, bridge or bypass the safety
systems.
WARNING
Procedure in the event of a fire
Leaking chemicals can irritate the skin and the eyes!
DANGER – Immediately wash affected areas of skin thoroughly
with soap and water.
Risk of poisoning by inhalation of vapours.
– Thoroughly irrigate eyes with clean water.
If the battery catches fire, toxic vapours will be relea-
sed. – 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, NOTE
retreating to a minimum distance of 5 m.
– Use respiratory protection. The battery must be moved to a safe area (5 m
– Call the fire brigade. away from buildings) by specially trained person-
– Water can be used to cool down the incipient fire. nel.
1
– Ensure there is sufficient distance between the
truck and any obstacles so that the truck is not
damaged when the crane is used.
To avoid short circuits, batteries with open ter-
minals or connectors should be covered with a
rubber mat.
– Attach battery (1) to suitable lifting gear (2).
6210_003-012
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 battery-
powered truck/device) and assigned to
packing group II.
NOTE
Storage
For information about the storage of lithium-ion
batteries, see the document entitled "STILL
lithium-ion technology properties, storage, trans-
portation and processes".
Li + Li +
Li + Li +
A B A B
386_000-011
1 Charging A Cathode
2 Discharging B Anode
NOTE
Charging process
During charging, lithium ions flow from the pos-
itive electrode (cathode) through the separator.
Lithium graphite is produced at the negative elec-
trode (anode); cobalt manganese and nickel
Discharging process
During discharging, lithium ions flow from the
negative electrode (cathode) through the sepa-
rator.
Graphite is produced at the negative electrode
(cathode); lithium metal oxide (CO, Mn, Ni)
is created at the positive electrode (anode)
→ electrical energy.
Main components
10 1
9
5 4
386_000-003
Exploded view
6 5
386_000-004
Temperature sensors
1 NTC 1 3 NTC 3
2 NTC 2 4 NTC 4
1 LED display
Time 1s 1s 1s 1s 1s 1s 1s 1s 1s 1s 1s 1s
Red/green LED Red Green
OFF/quiescent state (off) (off)
Battery reset 1x 1x
Module not detected by
master
Error
Flash procedure active 3x 3x
Normal operation - no
faults
.
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 Rext1
2 I-balance
3 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.
Charging state
Display Comment
(%)
First charging
state LED
flashes red: 3 2
0-2
the truck can
386_609-007
no longer be
moved. 1 Service LED
First charging 2 Temperature LED
state LED lights 3 Charging state LED
up red: drive to
> 2 - 10
the charging
station
immediately
Charging state
Display 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.
The battery management system (BMS) contains • Operating the battery module via the internal
various controllers that communicate with one CAN bus
another via CAN bus systems. The battery • Permanent Balancing
controller (BMC) is the main processor in this
system. Each battery module has its own battery The BMS contains independent CAN bus sys-
module controller (CSC). The BMS is powered by tems for data transfer between the controllers
the battery itself. and for communication with the truck.
Tasks of the battery controller (BMC) Internal CAN bus (CAN 2.0, 500 kB/s)
• Controlling and monitoring all battery functions • A CAN star circuit connects the controllers in
the technology compartment
• Communicating with the truck
• A CAN series circuit connects the battery
• Collecting all battery data and formatting it for
module controllers in the battery tray
the truck
• Recording all operating and diagnostic data External CAN bus (CANopen, 500 kB/s)
relating to the battery • Communication with the truck
• Processing the data supplied by the truck
CAUTION
CAUTION
Risk of fire!
Risk of short circuit!
Flammable fluids can be ignited by hot components.
The battery is located in an enclosed
– Do not use flammable fluids for cleaning.
and splash-proof battery tray. Excessive
water pressure or water and steam that – Follow the instructions of the cleaning material
are too hot can damage components. manufacturer.
Water ingress can cause a short circuit – Never clean brake resistors with cleaning materials,
and damage the battery. only clean them of dust without applying liquids.
– Always switch off the electrical system before Lithium-ion batteries do not require any special
cleaning. maintenance work. Regular cleaning according
to usage is recommended.
– Make sure that all openings of the battery that
can be closed are closed correctly. – Switch off the industrial truck and secure it
against being switched back on.
– Only use high-pressure cleaners with a
maximum output power of 50 bar and at a – Clear access to the battery in the industrial
maximum temperature of 85°C. truck.
– When using high-pressure cleaners, make – Check the condition of the connections.
sure there is a distance of at least 20 cm – When cleaning, wear protection goggles and a
between the nozzle and the object being dust mask if required.
cleaned.
– Blow out dust and dirt with low-pressure
– Do not aim the cleaning jet directly at adhesive compressed air or a vacuum cleaner.
labels or decal information.
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.
NOTE
NOTE
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 engage-
ment 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.
Battery charge
Battery discharge
NOTE
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.
UNominal UMeasured
48 V 26 to 39 V
80 V 48 to 72 V
X52
NOTE
NOTE
NOTE
Function checking
Checking that the battery male
connector is de-energised
Measuring equipment
• 2-pole voltage detector
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 perfor-
med by a service technician qualified to work with
high-voltage equipment.
Test values
Recommended Nominal voltage
Component Measurements Test values
test voltage UBatt
24 volts
Batt+
Battery 500 VDC Battery tray 48 volts 2.8 GΩ to 1 MΩ
Batt-
80 volts
.
NOTE
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.
Design BG 2.1
Technical data for battery group
2.1
Safety
Protection class IP6K9K
Fire protection rating External housing/13S cell module A2/B2
.
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
NOTE
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
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)
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.
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.
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.
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.
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
• 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)
NOTE
Weight: 10.5 kg
– Place the front module cover in position and
mask the lift hole (1).
Components BG 2.1
Tray cover - Battery group 2.1
Unit Value
Length mm 1030
Width mm 529
Height mm 22
Screw joint Piece 25
NOTE
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 "Remov-
ing/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.
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.
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.
Charging state
Display Comment
(%)
First charging
state LED
flashes red: 3 2
0-2
the truck can
386_609-007
no longer be
moved. 1 Service LED
First charging 2 Temperature LED
state LED lights 3 Charging state LED
up red: drive to
> 2 - 10
the charging
station
immediately
> 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.
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.
Removing
– Ensure that the electrical system is de-ener-
gised; 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).
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-ener-
gised; see the section entitled "De-energising
the system".
When reinstalling a battery display that has pre-
viously been removed, the following procedure
must be followed:
Schocksensor
G
Der Schocksensor teilt sich die Platine mit dem
(m/s²)
Display und ist mechanisch starr an den Batteri-
etrog angebunden.
Ein Schockereignis während der Ruhephase
(Lagerung oder Transport) wird ebenfalls reg- 15 G
istriert und gespeichert.
10 G
Batterie im Flurförderzeug verbaut
Schocklevel Reaktion
t
Ergebnis wird nicht
≤ 10 G im Fehlerspeicher der (min)
Batterie gespeichert. 386_609-012
Speichern des
Ereignisses im
Fehlerspeicher der
Batterie,
10 G - 15 G Senden von CAN-
Nachricht an das
Fahrzeug,
Reduzierung der
Fahrgeschwindigkeit
Starten der Batterie
nicht möglich,
>15 G
Reset durch
Servicetechniker nötig.
386_691-024
1 Housing
2 Pressure cap with bayonet catch
3 Membrane
4 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.
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.
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.
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.
Installing
DANGER
Dangerous electrical voltage!
Battery voltage is present between the POSITIVE
power connectors and the NEGATIVE power connec-
tors.
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.
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.
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).
NOTE
Installing
– Wear personal protective equipment.
– Use insulated tools.
NOTE
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.
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.
Installing
NOTE
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.
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.
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.
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:
1 Battery module connection
• Measurement of voltage + modules directly 2 Battery male connector connection
after 450 A fuse (S1-) X71 Connection BMC
• Measurement of voltage after connected X72 Voltage measurement
contactor K1 (K1+)
• Measurement of output voltage after con-
nected contactor K2 (K2-)
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.
Removing
– Ensure that the electrical system is de-ener-
gised; 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).
Installing
– Ensure that the electrical system is de-ener-
gised; see the section entitled "De-energising
the system".
Status LED
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 modu-
lation using PIN "feedback" and indicated by
the "ready" LED (2). The pulse width modula-
tion 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 tempera-
ture sensor, the LED is off.
Pre-charging
The BCM has an internal pre-charge circuit
for the intermediate circuit of the BCM. Pre-
charging 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 measure-
ment 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 per-
missible temperature range. If the truck does not
adhere to this value, the BCM system switches
off automatically to protect itself.
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.
Removing
NOTE
Installing
– Ensure that the electrical system is de-ener-
gised; 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
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.
The NTC resistor monitors the temperature and 1 Brake resistor 105 mΩ
provides feedback to the brake chopper module. 2 Connection to BCM "R-"
3 Connection to BCM "R+"
Technical data 4 Connection to contactor connectors "K1"/"K2"
Resistance value 105 mΩ
Resistance value
±10%
tolerance
Insulation resistance >50 MΩ
Operating voltage UMAX = 54 V (48 V)
Nominal voltage Unominal = 13 x 3.75 V
Final charged voltage 13 x 4.12 V
Test voltage (1 minute) UP = 1200 V DC
NTC resistance 10 kΩ
Dimensions (length / 503 mm / 100 mm /
width / height) 50 mm
.
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.
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.
Removing
– Measure the insulation resistance; see the
section entitled "Measuring the insulation
resistance".
– Ensure that the electrical system is de-ener-
gised; 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.
Installing
– Insert the brake resistor (1) in the right-hand
side of the guide (2).
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 1 LEDs (x2), BMC main processor
• Communication with the BCM 2 BMC
3 LEDs (2 pieces) BMC monitoring computer
X11 Diagnostics, CAN, contactors, BCM, SSV
X12 CSC
X13 Battery display / shock sensor
X14 Power supply
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.
Removing
– Measure the insulation resistance; see the
section entitled "Measuring the insulation
resistance".
– Ensure that the electrical system is de-ener-
gised; 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".
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)
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.
Removing
– Measure the insulation resistance; see the
section entitled "Measuring the insulation
resistance".
– Ensure that the electrical system is de-ener-
gised; 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".
Contactor assembly
When commissioning the truck, the contactors
are enabled as long as the battery is ready for
operation.
1 Contactor K1
2 Connector plug X94
3 Contactor K2
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.
Removing
– Ensure that the electrical system is de-ener-
gised; see the section entitled "De-energising
the system".
– Remove the protective cap (1).
– Disconnect the plug X94 (2).
Installing
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.
Removing
– Measure the insulation resistance; see the
section entitled "Measuring the insulation
resistance".
– Ensure that the electrical system is de-ener-
gised; see the section entitled "De-energising
the system".
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".
Electrical fuses
Main fuse
The main fuse on the positive power distribution
side has a rating of 450 A.
1 Fuse holder
F1 Main fuse (450 A)
1 Fuse holder
F2 BMC / SSV (20 A)
F3 CVS voltage measurement S1- (3 A)
F4 CVS voltage measurement S2+ (3 A)
F5 CVS voltage measurement S2- (3 A)
F6 Pre-charging for the brake chopper (3 A)
1 F20
386_609-015
1 SSV
F50 Control units supply (20 A) power transmis-
sion path (output side)
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.
1 Fuse holder
F1 Main fuse (450 A)
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.
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
Design BG 2.2
Technical data for battery group
2.2
Safety
Protection class IP6K9K
Fire protection rating External housing/13S cell module A2/B2
.
1 2
11
10
9 5
8
6
7
386_691-002
Battery safety
Battery safety is ensured by the following proper-
ties:
• 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
386_691-001
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
Spannungsfreiheit im Tech-
nikraum 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 Förder-
mittel verwenden.
Flachstecksicherung F2 ziehen
WARNING
Beim ziehen der Sicherung unter Spannung kann ein
kleiner Störlichtbogen entstehen.
– Sicherung mit Sicherungszieher entfernen.
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.
DANGER
Gefährliche elektrische Spannung!
Am Plus-Sicherungseingang liegt weiterhin Spannung
an.
Verhinderung von versehentlichem Berühren oder
Kurzschließen der noch spannungsführenden Ein-
gangsseite der Hauptsicherung.
– Bei Reparaturen im Technikraum der Batterie
muss nach dem Entfernen der Hauptsicherung
die isolierte Sicherheitsvorrichtung angebracht
werden.
Spannungsfreiheit im Tech-
nikraum prüfen
– Zweipoliger Spannungsprüfer an CVS-Mi-
nus (3) gegen Plus-Sicherungseingang (1)
anlegen.
Prüfergebnis: Elektrische Spannung anliegend.
– Zweipoliger Spannungsprüfer an CVS-Mi-
nus (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
• 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.
Flachstecksicherung F2 einsetzen
– Flachstecksicherung F2 (1) einstecken.
NOTE
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 Förder-
mittel verwenden.
Components BG 2.2
Tray cover - Battery group 2.2
Unit Value
Length mm 1030
Width mm 502
Height mm 22
Screw joint Piece 29
NOTE
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) herauss-
chrauben.
– Deckelschiene (3) abnehmen.
– Vorgang auf der gegenüberliegenden Deckel-
seite wiederholen.
– Zylinderschraube M6x25 (5) mit Unterlegblech
herausschrauben.
– Vorgang auf der gegenüberliegenden Deckel-
seite wiederholen.
– Zylinderschraube M6x25 (2) mit Unterleg-
blech-Kabelschacht herausschrauben.
– Trogedeckel (4) abheben.
Anbau
Vor dem Auflegend es Trogdeckels sichterstel-
len:
• 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 Trog-
deckels möglich!
Der Trogdeckel kann durch ungleichmäßiges Anzie-
hen der Befestigungsschrauben verziehen und die
Deckeldichtung undicht werden.
– Zuerst alle Befestigungsschrauben von Hand bis
zur Kopfauflage hineinschrauben.
– Befestigungsschrauben immer von der Mitte begin-
nend nach außen festschrauben.
– Unterschiedliche Anzugsdrehmomente beachten!
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.
Charging state
Display Comment
(%)
First charging
state LED
flashes red: 3 2
0-2
the truck can
386_609-007
no longer be
moved. 1 Service LED
First charging 2 Temperature LED
state LED lights 3 Charging state LED
up red: drive to
> 2 - 10
the charging
station
immediately
> 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
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 "Span-
nungsfreiheit herstellen".
– Trogdeckel abbauen, siehe Abschnitt
"Trogdeckel Abbau/Anbau".
– Leistungsverbinder Plus ausbauen, siehe Ab-
schnitt "Leistungsverbinder Plus Ausbau/Ein-
bau".
– Verbindungskabel Batterie-Display/Dis-
playelektronik (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 Klebestrei-
fen 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 "Span-
nungsfreiheit herstellen".
Beim Wiedereinbau des vorher ausgebauten
Batterie-Displays gilt:
– Prüfen, ob die Batterie-Displaydichtung (2)
unbeschädigt und wiederverwendbar ist. An-
sonsten durch eine neue Dichtung ersetzen.
Beim Ersetzen des ausgebauten Batterie-Dis-
plays 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 Batterie-
Displays umlaufend gleichmäßig ausrichten
und leicht auf dem Glaskörper andrücken.
– Verbindungskabel Batterie-Display/Dis-
playelektronik (3) auf der Rückseite des Bat-
terie-Displays (1) anschließen.
Schocksensor
G
Der Schocksensor teilt sich die Platine mit dem
(m/s²)
Display und ist mechanisch starr an den Batteri-
etrog angebunden.
Ein Schockereignis während der Ruhephase
(Lagerung oder Transport) wird ebenfalls reg- 15 G
istriert und gespeichert.
10 G
Batterie im Flurförderzeug verbaut
Schocklevel Reaktion
t
Ergebnis wird nicht
≤ 10 G im Fehlerspeicher der (min)
Batterie gespeichert. 386_609-012
Speichern des
Ereignisses im
Fehlerspeicher der
Batterie,
10 G - 15 G Senden von CAN-
Nachricht an das
Fahrzeug,
Reduzierung der
Fahrgeschwindigkeit
Starten der Batterie
nicht möglich,
>15 G
Reset durch
Servicetechniker nötig.
386_691-024
1 Housing
2 Pressure cap with bayonet catch
3 Membrane
4 Pressure "P"
Visual inspection
– Unscrew the M6x12 countersunk screws (2)
from the maintenance cover (1).
– Remove the maintenance cover.
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".
NOTE
386_691-011
Einbau
– Persönliche Schutzausrüstung anziehen.
– Isoliertes Werkzeug verwenden.
386_691-011
Temperature sensors
1 NTC 1 3 NTC 3
2 NTC 2 4 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)
Ausbau
– Isolationswiderstand messen, siehe Abschnitt
"Isolationswiderstand messen".
– Sicherstellen, dass die elektrische Anlage
spannungsfrei ist, siehe Abschnitt "Span-
nungsfreiheit im Technikraum herstellen".
– Trogdeckel abbauen, siehe Abschnitt
"Trogdeckel Abbau/Anbau".
– Leistungsverbinder Plus ausbauen, siehe Ab-
schnitt "Leistungsverbinder Plus Ausbau/Ein-
bau".
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 Förder-
mittel verwenden.
Einbau
NOTE
– 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 Förder-
mittel verwenden.
NOTE
Öffnen
– Isolationswiderstand messen, siehe Abschnitt
"Isolationswiderstand messen".
– Zylinderschrauben M6x10 (1) herauss-
chrauben.
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 Förder-
mittel verwenden.
Schließen
Vor dem Anbauen des Servicedeckels sichter-
stellen:
• Die Deckeldichtung in der Batterietrogwand
ist einwandfrei und sitzt korrekt in der Dich-
tungsnut.
• 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 Förder-
mittel verwenden.
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:
1 Battery module connection
• Measurement of voltage + modules directly 2 Battery male connector connection
after 450 A fuse (S1-) X71 Connection BMC
• Measurement of voltage after connected X72 Voltage measurement
contactor K1 (K1+)
• Measurement of output voltage after con-
nected contactor K2 (K2-)
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.
Removal
– De-energise the technology compartment;
see the section entitled "De-energising the
technology compartment".
– Disconnect the plugs X71 (2) and X72 (1).
Installing
– Insert the support for the current/voltage
sensor (2).
– Tighten the M6 nut (1).
Status LED
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 modu-
lation using PIN "feedback" and indicated by
the "ready" LED (2). The pulse width modula-
tion 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 tempera-
ture sensor, the LED is off.
Pre-charging
The BCM has an internal pre-charge circuit
for the intermediate circuit of the BCM. Pre-
charging 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 measure-
ment 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 per-
missible temperature range. If the truck does not
adhere to this value, the BCM system switches
off automatically to protect itself.
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.
Removing
4 3 11 12 1 2 3 4
NOTE
Installing
4 3 11 12 1 2 3 4
– Ensure that the electrical system is de-ener-
gised; see the section entitled "De-energising
the technology compartment".
– 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 BAT-
connector. 10 9 8 7 6 5 386_609-029
Tightening torque: 15 Nm
– Place the BAT+ cable (7) on the BAT+ connec-
tor.
– Tighten the socket head screw (6).
Tightening torque: 2.5 Nm
– Connect the BMC signal plug to the X41
connector (12).
NOTE
The NTC resistor monitors the temperature and 1 Brake resistor 105 mΩ
provides feedback to the brake chopper module. 2 Connection to BCM "R-"
3 Connection to BCM "R+"
Technical data 4 Connection to contactor connectors "K1"/"K2"
Resistance value 105 mΩ
Resistance value
±10%
tolerance
Insulation resistance >50 MΩ
Operating voltage UMAX = 54 V (48 V)
Nominal voltage Unominal = 13 x 3.75 V
Final charged voltage 13 x 4.12 V
Test voltage (1 minute) UP = 1200 V DC
NTC resistance 10 kΩ
Dimensions (length / 503 mm / 100 mm /
width / height) 50 mm
.
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.
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.
Removal
– Ensure that the electrical system is de-ener-
gised; 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).
Installation
– Insert the brake resistor (1) from above.
– Ensure that the brake resistor slides into the
lower latch (2).
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 1 LEDs (x2), BMC main processor
• Communication with the BCM 2 BMC
3 LEDs (2 pieces) BMC monitoring computer
X11 Diagnostics, CAN, contactors, BCM, SSV
X12 CSC
X13 Battery display / shock sensor
X14 Power supply
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.
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".
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)
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.
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".
Contactor assembly
When commissioning the truck, the contactors
are enabled as long as the battery is ready for
operation.
1 Contactor K1
2 Connector plug X94
3 Contactor K2
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.
Removal
– Ensure that the electrical system is de-ener-
gised; see the section entitled "De-energising
the technology compartment".
– Remove the protective cap (1).
– Disconnect the plug X14 (3).
– Disconnect the plug X94 (2).
Installing
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.
Removal
– Ensure that the electrical system is de-ener-
gised; 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".
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
Electrical fuses
Main fuse
The main fuse on the positive power distribution
side has a rating of 450 A.
1 Fuse holder
F1 Main fuse (450 A)
1 Fuse holder
F2 BMC / SSV (20 A)
F3 CVS voltage measurement S1- (3 A)
F4 CVS voltage measurement S2+ (3 A)
F5 CVS voltage measurement S2- (3 A)
F6 Pre-charging for the brake chopper (3 A)
1 F20
386_609-015
1 SSV
F50 Control units supply (20 A) power transmis-
sion path (output side)
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.
1 Fuse holder
F1 Main fuse (450 A)
1 Fuse holder
F2 BMC / SSV (20 A)
F3 CVS voltage measurement S1- (3 A)
F4 CVS voltage measurement S2+ (3 A)
F5 CVS voltage measurement S2- (3 A)
F6 Pre-charging of brake chopper (3 A)
1 F20
386_609-015
1 SSV
F50 Control units supply (20 A) power transmis-
sion path (output side)
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.
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 1
Index
g
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 M
Energy density . . . . . . . . . . . . . . . . . . . . VI
Main fuse
Final charged voltage . . . . . . . . . . . . . . VII
Replacing . . . . . . . . . . . . . . 21-60, 22-57
Final discharged voltage . . . . . . . . . . . . VII
Measuring the insulation resistance
Memory effect . . . . . . . . . . . . . . . . . . . VIII
Special tools . . . . . . . . . . . . . . 21-5, 22-5
Nominal capacity . . . . . . . . . . . . . . . . . VIII
Module holder
Nominal energy . . . . . . . . . . . . . . . . . . VII
Installing . . . . . . . . . . . . . . . . . . . . . 21-24
Nominal voltage . . . . . . . . . . . . . . . . . . VIII
Removing . . . . . . . . . . . . . . . . . . . . 21-22
Power source parallel connection . . . . . VIII
Power source serial connection . . . . . . . IX N
Primary cell . . . . . . . . . . . . . . . . . . . . . . IX
Nameplate of a lithium-ion battery . . . . . . . 00-1
Rechargeable battery . . . . . . . . . . . . . . . V
Recuperation . . . . . . . . . . . . . . . . . . . . . IX O
Regenerative braking . . . . . . . . . . . . . . . IX
Operating principle
Secondary cell . . . . . . . . . . . . . . . . . . . . IX
Charging/discharging . . . . . . . . . . . . . 00-8
I
P
Insulation resistance
Pin assignment
Measuring . . . . . . . . . . . . . . . . 21-5, 22-5
X51 . . . . . . . . . . . . . . . . . . . 21-48, 22-44
Intended use . . . . . . . . . . . . . . . . . . . . . . 00-4
X52 . . . . . . . . . . . . . . . . . . . 21-48, 22-44
L Positive power connector
Installing . . . . . . . . . . . . . . . . . . . . . 21-28
Leistungsverbinder Plus
Removing . . . . . . . . . . . . . . . . . . . . 21-27
Ausbau . . . . . . . . . . . . . . . . . . . . . . 22-20
Power cable
Einbau . . . . . . . . . . . . . . . . . . . . . . . 22-21
Installing . . . . . . . . . . . . . . . . . . . . . 21-62
Lifting tool
Removing . . . . . . . . . . . . . . . . . . . . 21-62
Attaching . . . . . . . . . . . . . . . . . . . . . . 01-4
Power cable 2.2
Removing . . . . . . . . . . . . . . . . . . . . . 01-4
Installing . . . . . . . . . . . . . . . . . . . . . 22-59
List of abbreviations . . . . . . . . . . . . . . . . . . . III
Removing . . . . . . . . . . . . . . . . . . . . 22-59
Lithium-ion batteries
Procedure in the event of a battery-related
Nameplate . . . . . . . . . . . . . . . . . . . . . 00-1
accident . . . . . . . . . . . . . . . . . . . . 00-5
Passive balancing . . . . . . . . . . . . . . 00-14
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
Schließen . . . . . . . . . . . . . . . . . . . . 22-28
Assembling the front module cover . . 21-12
Technology compartment
Closing the technology compart-
ment . . . . . . . . . . . . . . . . . . . . . 21-11 Battery group 2.1 . . . . . . . . . . . . . . . . 21-4
Inserting auto plug-in fuse F2 . . . . . . 21-11 Technology compartment 2.1
Installing the main fuse . . . . . . . . . . . 21-10 Closing . . . . . . . . . . . . . . . . . . . . . . 21-33
Special tools . . . . . . . . . . . . . . . . . . 21-10 Opening . . . . . . . . . . . . . . . . . . . . . 21-33
Terminating resistor
S 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
Spannungsfreiheit im Technikraum Fitting . . . . . . . . . . . . . . . . . . . . . . . 21-14
herstellen . . . . . . . . . . . . . . . . . . . 22-6 Removing . . . . . . . . . . . . . . . . . . . . 21-13
Flachstecksicherung F2 ziehen . . . . . 22-7 Trogdeckel 1.1 / 1.2
Hauptsicherung ausbauen . . . . . . . . . 22-7 Anbau . . . . . . . . . . . . . . . . . . . . . . . 22-12
Spezialwerkzeuge . . . . . . . . . . . . . . . 22-6 Trogdeckel 2.2
Technikraum öffnen . . . . . . . . . . . . . . 22-6 Abbau . . . . . . . . . . . . . . . . . . . . . . . 22-11
Special safety regulations . . . . . . . . . . . . . 00-2
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . 00-7 U
Support for the current/voltage sensor Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V
Installing . . . . . . . . . . . . . . . . . . . . . 22-32
Removing . . . . . . . . . . . . . . . . . . . . 22-32 V
Voltage transformer . . . . . . . . . . 21-56, 22-52
T
Installation . . . . . . . . . . . . . . . . . . . . 22-54
Technical compartment Installing . . . . . . . . . . . . . . . . . . . . . 21-57
Battery group 1.1 . . . . . . . . . . . . . . . . 22-4 Removal . . . . . . . . . . . . . . . . . . . . . 22-52
Battery group 1.2 . . . . . . . . . . . . . . . . 22-4 Removing . . . . . . . . . . . . . . . . . . . . 21-56
4 50988012057 EN - 12/2017
STILL GmbH
50988012057 EN – 12/2017