Hawker FLEX ELITE Bedienungsanleitung

OWNER’S MANUAL

www.hawkerpowersource.com

HAWKER FLEX®ELITE

TPPL BATTERY

CONTENTS

Introduction ...........................................3

Intended Use..........................................4

Battery Architecture..............................4

Operator Interfaces ...............................5

Safety......................................................7

Operational Data and Limits ................8

Handling .................................................9

Installation into Industrial Truck ..........9

Operation ...............................................10

Activation/Deactivation of Battery......10

Charging Battery ...................................11

Service and Maintenance .....................12

Troubleshooting ....................................12

Storage...................................................13

Description of Battery Labels...............14

Shipping HAWKER FLEX®Elite batteries

..14

Disposal and Recycling .........................15

Terms and Abbreviations......................15

The information contained in this document is critical

for safe handling and proper use of the HAWKER FLEX®

Elite battery for powering electrical industrial trucks. It

contains a global system speciﬁcation as well as related safety

measures, codes of behavior, a guideline for commissioning and

recommended maintenance. This document must be retained and

available for users working with and responsible for the battery. All

users are responsible for ensuring that all applications of the system are

appropriate and safe, based on conditions anticipated or encountered during

operation.

This owner’s manual contains important safety instructions. Read and understand

the sections on safety and operation of the battery before operating the battery and

the equipment into which it is installed.

It is the owner’s responsibility to ensure the use of the documentation and any activities

related thereto, and to follow all legal requirements applicable to themselves and the

applications in the respective countries.

This owner’s manual is not intended to substitute for any training on handling

and operating the industrial truck or HAWKER FLEX®Elite battery that may

be required by local laws and/or industry standards. Proper instruction and

training of all users must be ensured prior to any contact with the battery

system.

Refer to the abbreviations and terms at the end of this document.

For service, contact your sales representative or call:

1-877-7HAWKER (USA and Canada)

www.hawkerpowersource.com

Your Safety and the Safety of others is Very Important

wWARNING You can be killed or seriously injured if

you don’t follow instructions.

INTRODUCTION

INTENDED USE

Intended Use

HAWKER FLEX®Elite batteries are designed for

industrial truck applications only. Only

HAWKER®-approved chargers are to be used with

HAWKER FLEX®Elite batteries.

The truck harness used between HAWKER FLEX®

Elite batteries and the industrial truck is dictated by

the truck original equipment manufacturer (OEM).

The truck harness shall comply with UL 583

requirements for electrical current carrying

capability and truck interface requirements.

Compliance shall be conﬁrmed by the truck OEM.

wWARNING Installing the battery in a

non-UL 583 compliant truck is a ﬁre risk due to a

potential for improperly sized cable harnesses, and

will void your warranty.

Battery Architecture

The parts of the battery are shown in Figures 1 & 2.

Figure 1: External Battery Features

Figure 2: Battery Management System (BMS)

Connections

Harness connection (35 pins) provides connectivity

to:

• Power

• Voltage sense leads (X2)

• Current measurement sensor

• CAN bus (charger communication)

• T°C (temperature leads [X3])

• Charger plug detection leads (X2)

• Contactor control

• Fan control leads (X2)

• HMI port allows connectivity with all the Human

Machine Interface devices as the BBWC and

HAWKER®battery discharge indicator (BDI)

• Controller area network (CAN) open port to

interface with the truck CAN bus

The battery is a modular design made of 12-Volt

Thin Plate Pure Lead (TPPL) blocs, combined

in serial and parallel to provide the energy

content required for the application. Different

conﬁgurations are available or can be designed.

Please contact your local HAWKER®representative

for more information.

The battery is protected by the BMS packaged

inside the unit. This control module contains

safety components and logic to control the main

contactor, preventing the operation of the battery

in unsafe or abusive conditions.

Figure 1

Cooling Fan

Primary

Charge Cable

Secondary

Charge Cable

(Connector type and appearance may vary.)

Figure 2

Truck Interface

Terminal

Operator

Interface Terminal

BATTERY ARCHITECTURE

Battery Architecture (cont.)

Safety Features:

• Functional safety qualiﬁed electronic monitoring

and control system to ensure safe electrical

operation within voltage, current and temperature

limits.

• A safe shut-off strategy to respond if operating

limits are violated (voltage, current, and

temperature).

• Charge circuit to prevent arcing if improper

disconnection is attempted.

• Dedicated handling/lifting points.

• Dedicated bloc ventilation to enhance

performance and energy throughput even in

high-temperature applications.

Interface Terminals: There are multiple low-voltage

interfaces on the battery exterior which must be

connected during commissioning, depending on

the end-user requirements:

Charge Interface Terminal: This is a required

connection for all HAWKER FLEX®Elite batteries.

This interface connects the charging adapter to

the battery system, allowing CAN communication

between the battery and charger.

Interface Terminals (cont.):

Truck Interface Terminal: This interface provides

speciﬁc communications for integration with the

truck’s state of charge (SoC) related features and

controls. This truck interface is not a requirement

from HAWKER®but may be required by the truck

manufacturer.

• Interlock: Allows the truck to send a signal to

tell the battery to shut down.

• Early Warning Signal: Battery will provide a

signal to the truck 10 seconds before battery

shutdown.

• CAN Open: Operating communications for

protocol sharing between truck and battery.

NOTE: If the use of this signal as the interface

with the truck is necessary, but not previously

discussed with HAWKER®, please contact your

HAWKER®service representative for support prior

to installation. Application prequaliﬁcation and a

specialized cable could be required.

Operator Interface Terminal: 12-pin amphenol

connector to HAWKER® ABI device or battery

discharge indicator (BDI).

The low-voltage interfaces are protected by a 0.5A

fuse.

NOTE: Any unused connector must be protected

by a threaded cover to prevent the ingress of

contaminants or foreign material.

Operator Interfaces

An operator interface is required to be installed

in the truck cabin for ease of use and to ensure

the operator is alerted to any visual or audible

warnings such as low SoC. This in-cabin interface

can be either the BDI or the HAWKER® ABI smart

battery dashboard.

This requirement for an in-truck interface can only

be eliminated if full industrial truck OEM integration

options are deployed that allow the truck’s

preexisting operator interfaces to be utilized. Truck

integrations require prequaliﬁcation and approval

from both HAWKER®and the truck OEM.

During operation as the SoC decreases, the

operator interfaces will provide an audible alarm

and visual warnings when the battery drops to the

Warning SoC level. After the battery continues to

fall below the alert level, the alarm will increase

in speed. Continuing to run the battery without

charging will ultimately result in the battery

deactivating due to low SoC.

The buzzer and LED behavior for the devices are as

follows:

• Warning SOC ON 1 sec./OFF 1 sec.

• Alert SOC ON 0.5 sec./OFF 0.5 sec.

• BMS error ON 0.1 sec./OFF 0.1 sec.

OPERATOR INTERFACES

Operator Interfaces (cont.)

With truck integration, the CAN cable must be

connected from the CAN port on the battery

(Figure 2 [see page 4]) to the truck. With truck

integration, warnings and alerts will follow the truck

OEM’s structure.

External BDI:

This device can be installed outside of the battery

compartment to allow operators to view the SoC

and the presence of a battery error as well as to

provide easy access to an activation/deactivation

button. The series of lights will indicate the SoC,

whilst audible alarms will notify the operator

that the battery requires recharging or that there

are battery errors. Continued operation after the

BDI indicated low SoC will ultimately result in

deactivation of the battery due to low SoC. The

BDI must be permanently and securely ﬁxed in

a position for the operator to view the BDI for

information and access the button.

Figure 3: External BDI

Figure 4: SoC indicator screen

Truck iQ™ Smart Battery Dashboard:

Figures 5 & 6: HAWKER®ABI smart battery

dashboard

HAWKER®Advanced Battery Interface™ Dashboard:

The HAWKER®ABI smart battery dashboard is an

operator interface that provides operators with

more detailed battery information compared to

the BDI. The HAWKER®ABI device includes the

activation/deactivation button, as well as audible

and visual alarms. The HAWKER®ABI device

must be installed per the installation instructions

provided with the HAWKER®ABI device unit. The

HAWKER®ABI device must be permanently and

securely ﬁxed in a position where the operator can

view the information and access the button.

Low SOC Audible Warnings

SOC Buzzer Stop Condition

Warning ON/OFF 1 sec. Normal SOC/On Charge

Alert ON/OFF 0.5 secs. Normal SOC/On Charge

Refer to the HAWKER®ABI smart battery device

manual for further information.

CAN bus Connectivity

The HAWKER FLEX®Elite battery can be integrated

into an OEM industrial truck CAN bus system which

allows full integration of the battery.

Figure 3

Figure 6

USoC 100% <75% <50% <25% Low Soc

or Error

Figure 4

Figure 5

SAFETY

Operator Interfaces (cont.)

Please contact your local HAWKER®Representative

for this option. This requires engineering

consultation between HAWKER®and the industrial

truck OEM.

HAWKER®MOD-iﬁ™ Smart Device App:

All data relating to the battery cycle life are stored

in the BMS (Figure 7).

The BMS data can be read wirelessly

through the HAWKER®MOD-iﬁ™

Smart Device App available

on both iOS®and Android™

platforms. Contact your HAWKER®

Representative for more information.

Safety

Important Safety Instructions

• Read all safety and operation instructions before

operating this battery.

• Anybody involved in handling, operating,

or maintenance of this battery must receive

appropriate training and use appropriately rated

tools and personal protective equipment.

• Follow all regulatory requirements for handling

electrical systems. The voltage of an electrical

system may impact what regulations are

applicable.

• Do not over-discharge or overcharge HAWKER

FLEX®Elite batteries as this poses a substantial risk

of damaging the battery.

• Only store and operate the battery within the

limitations given in the sections on operational

data and environmental limits.

• Keep the battery away from heat and ignition

sources.

• Do not charge or operate the battery in hazardous

environments.

• Only handle and store the battery in a dry

environment.

• Store only in monitored areas with suitable ﬁre

control and protection per local requirements,

including local ﬁre regulations.

• Recharge or operate only in monitored areas

with suitable ﬁre control and protection per local

requirements, including local ﬁre regulations.

• Recharge requires ventilation (refer to

local standards or contact your HAWKER®

Representative).

• Do not customize the battery hardware or software

as supplied by HAWKER®; or your warranty may

be voided.

• Only operate with HAWKER®-approved interface

devices.

• Service of the battery must only be performed by

HAWKER®-approved technicians.

• Dismantling of the battery is not authorized except

by qualiﬁed HAWKER®personnel due to potential

hazards involved; or your warranty may be voided.

• In the case of any error that cannot be reset,

do not attempt to continue the operation of the

battery until support and direction is provided by

HAWKER®; or your warranty may be voided.

• Do not leave the truck idle in temperatures below

the battery operating temperature as this may

result in the truck becoming nonoperational.

• Do not attempt to operate this battery in

temperatures above the operating range.

• Do not expose the battery to extended periods

of direct sunlight that allow the temperature of

the battery to rise above the storage or operating

temperatures of the battery.

• Do not operate the battery outdoors without

suitable weatherproof protection.

• Do not immerse the battery in water or clean the

battery using pressurized water.

• Do not operate the battery in condensing

environments.

• Do not install the battery on the underbody of an

electrical industrial truck.

Figure 7

SAFETY

Safety (cont.)

Interoperation with truck and battery charger

• The instructions in this owner’s manual do not

replace or supersede the instructions for the

truck and battery charger.

• The operation limits given in this owner’s manual

do not replace or supersede the permissible

operation parameters of the industrial truck or

charger.

• Only charge this battery with

HAWKER®-approved chargers for HAWKER

FLEX®Elite batteries.

• The battery must be installed in a truck with

appropriately sized cables.

Risks posed during normal operation

• This battery is designed to be stable and tolerant

to the applications within the scope laid out

in the operating conditions, however, battery

systems are inherently hazardous.

• Do not short the battery terminals. A shorting

event with a high current may occur, leading

to potential explosions and various hazards for

the operator. A resulting electric arc fault may

emit an intense hot ﬂash of infrared, visible, and

ultraviolet light. Molten and vaporized metal

may be ejected. Toxic fumes may be released.

Components may become extremely hot.

• The weight and size of the battery make it

cumbersome to handle.

• Always properly restrain the battery. Failure to

restrain the battery may result in the battery

shifting or dropping. Additionally, this may result

in the battery crushing, pinching, or impacting

personnel or nearby equipment.

Damaged batteries

• Exposure of the battery to conditions outside of

its operational and environmental limits poses a

substantial risk of damage to the battery. Do not

assume damage to the battery will be apparent.

• If the battery experiences conditions outside of

the allowable limits as stated in this document,

immediately cease and do not resume operation,

and contact your HAWKER® Representative.

• If the mechanical integrity of the battery is

compromised (e.g., penetration of case, rupture

of the case, etc.) immediately cease and do not

resume operation of the battery. Contact your

HAWKER® Representative.

• Stop operation of the battery if there is a crush,

pinch, cut, or other damage to the power cables

or power connectors.

• If any material, such as liquid electrolyte, from

a damaged battery comes into contact with a

person’s skin or eyes, rinse the affected areas

with clean water for at least 15 minutes. Then

immediately obtain medical attention.

• If any material, such as liquid electrolyte, from

a damaged battery comes into contact with the

mouth or is swallowed, rinse out the mouth

as well as the area around the mouth. Then

immediately obtain medical attention.

• Contact with heated gases or components of

a damaged battery may cause serious thermal

burns. Treat any thermal burns, then immediately

obtain medical attention.

Additional information can be found in the safety

data sheet for the VRLA batteries, SDS 853027H.

Operational Data and Limits

• Nominal capacity: Nominal Capacity (C6) :

840 Ah

• Nominal voltage: 36V

• Conﬁgurations: 3 blocs series 3 blocs parallel

(3s3p)

• Max charging current: 588 Amps

• Discharge current (continuous): 1x C6, up to a

max of 320 A (limited by traction cable harness)

• Max energy throughput per day: up to 180% C6

HANDLING AND INSTALLATION

Handling

General Handling Considerations

• Handling of the battery is only allowed by trained

personnel that are familiar with the potential

risks of traction batteries for industrial trucks and

for lifting heavy loads.

• Avoid sudden acceleration, deceleration, drops,

and other mechanical abuse conditions while

handling the battery.

• Handling must only be performed after the

battery is disconnected from all electrical loads

and charge sources.

• Prior to lifting, secure all connectors and cables

so that they will not be crushed, pinched,

or otherwise damaged during the lift. User

interfaces may be removed prior to handling.

• Appropriate PPE must be worn during all lifts.

• Appropriate lifting methods and tools that can

safely lift and control the load must be checked

prior to all lifts. Tools must be properly rated for

weight.

• Attach lifting tools to the tray lifting points.

• The battery must only be lifted vertically. Do not

allow the battery to swing during lifting.

• The operational and safety instructions of the

lifting gear manual must be respected.

• If the battery is being handled while installed

on a truck, for instance during the battery

installation or removal operation, the truck must

be secured to prevent movement.

Installation into Industrial Truck

Mechanical Installation

• This battery is designed to be a direct

replacement of a standard lead-acid battery

intended to power an electric industrial truck.

• Upon receipt of the battery, it must be checked

for any visible signs of damage to the battery

and all cables, plugs, and accessories.

• Before installation, check that the battery is

supplied with the appropriate cable harness to

connect the battery to the industrial truck.

• Ensure that the battery weight and center of

gravity requirements per the truck manufacturer

are followed.

• The battery must be handled in a way that

mitigates the risk of drop events and crashes.

The correct tools, lifting points, and methods

should be used.

• After placement of the battery into the truck’s

battery compartment, the technician must ensure

the battery is mechanically secured in the truck

against movement as speciﬁed by the industrial

truck manufacturer. After the battery is secured

in the truck’s battery compartment, the battery

unit must be checked again to ensure no cables,

wires, or plugs were crushed, pinched, cut or

damaged during insertion.

Electrical Installation

• The battery must be connected with the

appropriate cables and connector to the

industrial truck per the truck manufacturer’s

recommendation.

• Only use HAWKER®-approved fasteners,

connectors, cabling, and plugs with this battery.

• The cable dimensioning and DC connecting plug

will vary depending on the truck and end-user

requirements. The truck harness shall comply

with relevant requirements for current carrying

capability and truck interface requirements.

Compliance shall be conﬁrmed by the truck’s

OEM.

wWARNING Defective cables and connectors

can result in functional issues and/or severe safety

hazards such as short circuits and/or ﬁre. Cables

and connectors must be regularly inspected for any

damage or issues. Cables and connectors should

only be repaired or replaced by an authorized

HAWKER® Representative using the correct factory

replacement parts. No substitution is allowed.

OPERATION

Operation

While HAWKER®has used reasonable efforts

towards the application of legal requirements, this

documentation should neither be considered nor

relied upon as legal advice.

Anybody using this battery must be trained on the

aspects of the battery they are responsible for as

required by local laws and regulations.

The battery must be handled, operated, stored,

maintained, and serviced in accordance with the

instructions in this owner’s manual.

wWARNING Failure to follow the instructions in

this owner’s manual can result in serious damage

to the battery and may result in serious injury.

Failure to follow the instructions in this owner’s

manual or using parts that are non-original will

void the battery warranty.

Opportunity charging is highly recommended

to maximize the daily operating capability of the

battery. It will also optimize the service life of the

battery by decreasing the discharge window of the

battery during discharge.

The capability of the battery to power the truck

decreases at low SOC. If the truck is operated at

a low SOC, this may result in the battery shutting

down with or without a 10-second warning. If this

occurs, reactivate the battery and slowly drive

the truck to a matching charger to connect and

recharge.

In contrast to traditional lead acid batteries, it is

beneﬁcial to operate HAWKER FLEX®Elite batteries

at a partial state of charge with frequent and rapid

opportunity charges during periods of non-use

(operator breaks, shift changes, etc.).

This battery is designed to be charged indoors in

the truck.

The battery temperature inﬂuences the capacity of

the battery. For example, run time may be reduced

at lower temperatures. Battery temperatures at the

extreme ends of the temperature limits as stated in

this owner’s manual will inﬂuence performance.

Respect all visual and audible warnings from the

user interface devices.

Activation/Deactivation of Battery

The BMS will deactivate automatically when a

no-load condition is detected for a default setting

of 156 continuous hours to ensure that an unused

battery is not deeply discharged.

Activation:

During use: Provided the pack is not connected to a

charger and there are no battery errors, the battery

will automatically switch to the traction state

applying power to the truck. In all cases, a short

press of about half a second is required.

During charging: The battery is activated when it

is plugged into the charger. This allows battery

activation and charging even without previous

activation of the battery by other measures above.

Deactivation:

Extended non-use: The battery will deactivate after

a default of 156 hours when there is less than a

3 A current draw. If different values for these are

desired, contact your HAWKER® Representative to

make adjustments.

Manual deactivation: Ensure the equipment is shut

down prior to deactivating the battery. To manually

deactivate the battery, press the button on any user

interface for 3 to 5 seconds. Holding for longer

may result in turning the unit OFF and then back

ON.

wWARNING When deactivating the battery,

there is approximately a 20-second shutdown

sequence in which an audible alarm will be heard.

Pushing the button again during this time will stop

the shutdown procedure and return the pack to a

fully ON state.

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