User Manual - Battery - 20220719 - HES

Please read the manual carefully before installing/operating our product.
Please keep this manual properly for future reference.
Neglect of manual instruction may not only damage

the battery system and charger, but also bring hazard
to operator and other facilities.
Benefits of LiFePO4 Battery system

• Quick Charging
• Opportunity Charging
• Low maintenance
• Extra life cycles
• Highly safety
EK22EN-07/2022
Content
Chapter 1 Introduction ..................................................................................................... 1
Scope of use ..................................................................................................................................................................1
Description of use and climatic conditions .........................................................................................................1
Definition of terms used for responsible persons ............................................................................................ 2
Customer................................................................................................................................................................... 2
Professional Personnel .......................................................................................................................................... 2
Competent person ................................................................................................................................................. 2
Explanation of technical terms ................................................................................................................................ 2
SOC..............................................................................................................................................................................2
Full charge of the battery.....................................................................................................................................2
Chapter 2 Safety ..............................................................................................................3

Safety Instructions ....................................................................................................................................................... 3
Customer obligations ............................................................................................................................................ 3
Personnel qualification requirements ...............................................................................................................3
Battery handling ...................................................................................................................................................... 3
Responding to emergencies ....................................................................................................................................5
Fire-fighting measures ..........................................................................................................................................5
First aid measures ................................................................................................................................................... 6
Environmental protection ......................................................................................................................................... 6
Recycling....................................................................................................................................................................6
Chapter 3 Overview ......................................................................................................... 7

General View of a typical traction battery ...........................................................................................................7
Battery types ................................................................................................................................................................. 8
Battery nameplate ....................................................................................................................................................... 9
Chapter 4 Operation ...................................................................................................... 10

Safety matters and precautions ............................................................................................................................10
Battery transportation ..............................................................................................................................................10
Battery transportation requirements ..............................................................................................................10
Battery Installation .................................................................................................................................................... 11
Battery display............................................................................................................................................................11
EK22EN-07/2022 1
Color touch screen LCD ..................................................................................................................................... 11
Monochrome LCD................................................................................................................................................15
Power on and power off the battery .................................................................................................................. 16
Pre-use inspection ....................................................................................................................................................17
Charging the battery................................................................................................................................................17
Battery storage ...........................................................................................................................................................18
Disposal of battery ....................................................................................................................................................18
Installation guide of charger ................................................................................................................................. 19
Chapter 5 Maintenance ................................................................................................. 21

Battery maintenance operations ..........................................................................................................................21
Inspection of the electronic system .................................................................................................................... 21
Trouble shooting .......................................................................................................................................................22
Monochrome LCD................................................................................................................................................22
Error codes list ........................................................................................................................................................... 23
Monochrome LCD................................................................................................................................................25
EK22EN-07/2022 2
Chapter 1 Introduction
Scope of use
This manual is applicable to the lithium-ion power battery developed and produced by
Lithium-Ion Battery, and it contains the necessary tasks and procedures for power
batteries. Please directly contact your dealer for any items not included herein.
This manual is designed to be used by the customer, professional personnel and
qualified persons.
Persons performing the following tasks must read and use this manual:
• Transportation and storage
• Installation
• Use
• Routine maintenance and servicing
• Diagnostics and troubleshooting
• Recycling
Description of use and climatic conditions
• Working environment temperature -20℃--50℃

• Charging environment temperature 0℃--50℃
• Customized battery for cold storage application -45℃~50℃
If your equipment has to be operated beyond above temperature range, please consult your
dealer.
EK22EN-07/2022 1
Definition of terms used for responsible persons
Customer
Persons who use the product or requests service.
Professional Personnel
Trained and qualified member of personnel who has been authorised by the customer,
with professional knowledge on electrical engineering and the electrician certificate.
Professional personnel shall be familiar with the product, or relevant laws and
regulations, and able to complete relevant work on the product independently or with the
assistance of the after-sales personnel.
Competent person
Trained and qualified member of personnel who is able to use the product independently,
identify potential risks during product operation based on their experience and familiarity
with relevant laws and regulations, and prevent these potential risks.
Explanation of technical terms
SOC
Stage of Charge, hereby refers to the proportion of residual charge in the battery.
Full charge of the battery

In case of no error, the battery will be charged to SOC 100% and the charger will
automatically stop charging.
EK22EN-07/2022 2
Chapter 2 Safety
Safety Instructions
Customer obligations
• During the process of transportation, storage, installation, operation, routine
maintenance and troubleshooting, the customer is obliged to meet the following
requirements:
• The age of the employee shall meet the requirements of local law;
• Relevant laws and regulations on occupational safety must be observed;
• Only authorised persons shall be allowed to perform relevant work;
• Relevant persons must wear personal protective gear and inspections must be
carried out to check whether this requirement has been met;
• Read the safety-related chapters of this manual;
• Hazard stickers must remain complete and clear throughout the life cycle of the
product.
Personnel qualification requirements

Refer to the table below for the personnel qualification requirements for different tasks:
Battery handling
• Batteries are designed to be recharged. However, improperly charging a battery may
cause the battery to flame. When charging the battery, use dedicated chargers and
follow the specified conditions.
• Never disassemble or modify a battery.
• Do not immerse, throw, and wet a battery in water.
• Should a battery unintentionally be crushed, thus releasing its contents, rubber
gloves must be used to handle all battery components. Avoid the inhalation of any
vapors that may be emitted.
• Short circuit causes heating. In addition, short circuit reduces the life of the battery
and can lead to ignition of surrounding materials. Physical contact with to
EK22EN-07/2022 3
short-circuited battery can cause skin burn.
Do NOT short circuit positive and negative pole at any time.
Non-professionals not allowed to make maintenance.
Do NOT wear watches and other metal products during repair.
Your battery is sealed according to IP54,

Do Not splash water on the battery.
Do NOT damage battery cells by penetration or throw into fire, etc.
Keep away from highly corrosive, flammable environment and heat source.
EK22EN-07/2022 4
Responding to emergencies
 Stay away from battery at soonest and report immediately to HSE department.
 Make following actions only when personnel safety is guaranteed,
• If the battery wire harness is on fire, put out fire by carbon dioxide or dry
powder fire extinguishers
• If the battery is on fire, put out fire with a high-pressure water gun from
distance
• If smoke is inhaled, please transfer to hospital as soon as possible
 Notify the dealer of equipment for further treatment.
If the fire is caused during charging, ensure the power supply is cut off before perform any
actions.
Fire-fighting measures
Unusual Fire and Explosion Hazards:

Battery may explode or leak potentially hazardous vapors subject to: exposed to
excessive heat (above the maximum rated temperature as specified by the manufacturer)
or fire, over-charged, short circuit, punctured and crushed.
Hazardous Combustion Products:
Fire, excessive heat, or over voltage conditions may produce hazardous decomposition
products. Damaged batteries can result in rapid heating and the release of flammable
vapors.
Extinguishing Media:
Dry chemical type extinguishers are the most effective means to extinguish a battery fire.
A CO2 extinguisher will also work effectively.
Fire Fighting Procedures:
Use a positive pressure self-contained breathing apparatus if batteries are involved in a
fire. Full protective clothing is necessary. During water application, caution is advised as
burning pieces of flammable particles may be ejected from the fire.
EK22EN-07/2022 5
First aid measures
Skin contact:
Not anticipated. If the battery is leaking and the contained material contacts the skin,
flush with copious amounts of clear water for at least 15 minutes.
Eye contact:
Not anticipated. If the battery is leaking and the contained material contacts eyes, flush
with copious amounts of clear water for at least 15 minutes. Get medical attention at
once.
Inhalation:
Not anticipated. If the battery is leaking, remove to fresh air. If irritation persists, consult a
physician.
Ingestion:
Not anticipated. If the battery is leaking and the contained material is ingested, rinse
mouth and surrounding area with clear water at once. Consult a physician for treatment
at once.
Environmental protection
Recycling
Customers shall observe the following requirements when recycling the product:
• The specific environmental protection laws of the country or region where the
product is used must be observed;
• Waste parts and components shall be sent to qualified local recycling organizations
authorised by the government for recycling.
EK22EN-07/2022 6
Chapter 3 Overview
General View of a typical traction battery
Your Battery may vary from above due to most of batteries are customized.
Item Description Function
Monitor of battery status.
1 Display with Switch & Buzzer Power on/off battery
Alarm when fault
2 Discharging plug Connected to truck and power goes through
3 Battery tray The container of battery modules and electrical components
4 Display communication cable Display power and data cable
5 Calibration CAN CAN port for checking and updating BMS data or firmware
6 Charging CAN CAN port for communication between BMS and charger
7 Charging plug Connected to charger during charging

A mechanical valve to release internal pressure when there
8 Safety valve
is an accident of cells
9 Antenna To strengthen the signal telematics module of BMS
EK22EN-07/2022 7
Battery types
Standard MSD type and customized batteries are all provided.
MSD hereby means “Minimal Standard Dimension”.
EK22EN-07/2022 8
Battery nameplate
EK22EN-07/2022 9
Chapter 4 Operation
You must carefully read and follow these operating instructions to ensure the
safe and reliable long-term operation of your battery system.
Safety matters and precautions
You must follow the instructions below, in addition to the safety precautions in Chapter
Two:
• The charging and discharging currents must not exceed maximum current
specifications.
• Avoid charging in direct sunlight.
Battery transportation
According to PACKING INSTRUCTION 965 ~ 967 of IATA DGR 60th Edition for
transportation, the special provision 230 of IMDG (inc Amdt 38-16). The batteries should
be securely packed and protected against short-circuits. Examine whether the package
of the containers are integrated and tighten closed before transport. Take in a cargo of
them without falling, dropping, and breakage. Prevent collapse of cargo piles. Don’t put
the goods together with oxidizer and chief food chemicals. The transport vehicle and
ship should be cleaned and sterilized before transport. During transport, the vehicle
should prevent exposure, rain and high temperature. For stopovers, the vehicle should
be away from fire and heat sources. When transported by sea, the assemble place
should keep away from bedroom and kitchen, and isolated from the engine room, power
and fire source. Under the condition of Road Transportation, the driver should drive in
accordance with regulated route, don’t stop over in the residential area and congested
area.
Battery transportation requirements

• The battery should be rainproof, waterproof and shockproof during transport.
• Battery shall always stay in up-right position during transportation.
• Please pay attention to weight limit.
• Temperature range during transportation : -10℃-- 40℃
Lithium Battery is Class 9 DGR commodity, you may

need to comply with local safety regulation
EK22EN-07/2022 10
Battery Installation
Make sure all is in right situation while installing battery into truck.
 Ensure your battery is power off during installation.
 Make sure battery is installed and removed by authorised maintenance personnel.
 Choose proper hanger and lifting equipment tool according to the weight of battery,
can find the weight on the nameplate of battery.
 Ensure there is no tools or other parts on the battery to avoid falling out or short
circuit.
Battery display
Color touch screen LCD
1. The main interface displays SOC (‘100%’ in figure)

2. Real time Voltage (‘85.6’ in figure, unit is V)
3. Real time Current, either charge or discharge (‘100.0’ in figure, unit is A)
4. Battery Module Temperature (‘0℃’ in figure)
5. Time (’09:28’, BMS time calibration required for different time-zone)
EK22EN-07/2022 11
 Touch the screen and select or
button, slide among different

interface styles
 Restart the battery, last style remains.
 Select button, enter the

engineering interface.
 Information such as battery total
voltage, SOC, current, maximum cell
voltage, minimum cell voltage,
maximum cell temperature, minimum
cell temperature will be demonstrated
in the main screen.
 Error description will be displayed on
the top of the screen.
 Select button, enter to ‘Setting’

interface.
 Language selection, Chinese or
English.
 Brightness of screen is also
adjustable
EK22EN-07/2022 12
 Touch and select button, enter
the ‘Cell voltage’ interface.

the ‘Cell temperature’ interface.
 Temperature of cells on show, unit
is ℃.

the ‘Heating temperature’ interface.
 Heater is optional inside battery
system, usually for batteries with
“ Cold-Storage” option.
EK22EN-07/2022 13
the ‘Relay status’ interface.

the ‘Charging information’ interface.
 Touch and select button,

enter the ‘Others’ interface.
 More information will be available by
enter different menus.
EK22EN-07/2022 14
Monochrome LCD
1. The main interface displays SOC (“80%” in figure)

2. Voltage (“26” in figure, unit is V)
3. Communication status (↑↓in figure)
4. Working hour of “2.4” (The unit is hour)
EK22EN-07/2022 15
Power on and power off the battery
 Power on
Press the switch button on the display box to power on the battery
• If no fault detected by BMS, it’s good to go on.
• If any fault detected by BMS, error code will occur, the discharge contactor will not
close.
 Power off
Press the same switch button for seconds until power off the battery.
Power switch
Color Touch Screen Monochrome LCD

(Version 2021)
External Battery Display
We have other batteries whose battery display, horn and switch are placed on top of the battery
itself with the same function.
EK22EN-07/2022 16
Pre-use inspection
 Ensure your battery is securely connected with equipment.

 Switch on the battery system before switch on the equipment.
 Check the battery display and ensure there is no error code existing.
 If SOC is below 50%, recommend to charge to minimum 50% before operate your
equipment
 When SOC reaches down to 15%, 10% and 5%, audible alarm will be triggered with
increasing frequency , do charge immediately
 If cell voltage drops down to 2.7V, BMS will cut off the battery system to avoid
over-discharge.
 Switch off equipment before switch off battery.
Charging the battery
 Ensure battery is “ON” before charging.

 Ensure your equipment (forklift) is switched off.
 Connect the battery and charger securely.
 Switch on the charger.
 When it's full charged, it will stop by itself and the charging current is 0A. Disconnect
directly.
 If you want to use the battery/forklift during charging, when not full charged, please
press Stop/Pause button to stop charging first, then disconnect the plug when
charging current is 0A.
The charging current will ramp to rated current in the first minute.
There is low/high temperature protection in charging process and the current will less
than rated current if battery temperature is too low or too high. 48V200A charging
process for example,
Battery temperature (℃) Charging current (A)
T≤0 0
0<T≤5 60
5 < T ≤ 10 120
10 < T ≤ 15 160
15 < T ≤ 55 200
55 < T ≤ 65 90
T > 65 0
EK22EN-07/2022 17
Battery storage
• Batteries should be separated from other materials and stored in a noncombustible,

well ventilated, sprinkler-protected structure with sufficient clearance between walls
and battery stacks. Do not place batteries near heating equipment, nor expose to
direct sunlight for long periods.
• Do not store batteries above 35℃ or below –20℃. Store batteries in a cool (about
20±5℃) in a long time, dry and ventilated area that is subject to little temperature
change. Elevated temperatures can result in reduced battery cycle life. Battery
exposure to temperatures in excess of 60℃will result in the battery venting
flammable liquid and gases.
• Keep batteries in original package until use and do not jumble them.
• Recommended SOC range for battery system storage: 50%-80%.
• Re-charge every 6 months.
Battery system shall be stored in below environment:

• Low humidity
• No direct exposure to sun-light
• Rain-proof
• Remote from heat source
Disposal of battery
• Disposal of the battery should be performed by permitted, professional disposal firms

knowledgeable in Federal, State or Local requirements of hazardous waste
treatment and hazardous waste transportation.
• The battery should be completely discharged prior to disposal and/or the terminals
taped or capped to prevent short circuit. When completely discharged it is not
considered hazardous.
• The battery contains recyclable materials. Recycling options available in your local
area should be considered when disposing of this product, through licensed waste
carrier.
EK22EN-07/2022 18
Installation guide of charger
AC Input Connecting
The connecting types:
Spec. Connection method
3KW series Single phase 3 wire system
Three-phase Four wire system,

Industrial socket or Y terminals
5~30KW series
Three-phase Five wire system,
Industrial socket or Y terminals
 You need to install the AC socket fittings.

 Need to be installed by professional electricians.
Recommended requirements for AC input cables and air switch as below,
Air switch
Charger Model Input voltage Grid type Input cable size Input current
/Breaker
24V50A AC220V±15% Single Phase 2.5mm2 16A-2p <=10A
24V100A AC220V±15% Single Phase 4mm2 32A-2p <=14.6A
48V50A AC220V±15% Single Phase 4mm2 32A-2p <=14.4
72V35A AC220V±15% Single Phase 4mm2 32A-2p <=15.3A
24V150A AC220V±15% Single Phase 6mm2 32A-2p <=24A
48V100V AC220V±15% Single Phase 6mm2 40A-2p <=29A
24V150A AC380V±15% Three phase four wire 2.5mm2 16A-3p <=7.2A
48V80A AC220V±15% Three phase four wire 4mm2 32A-2p <=14.2A
EK22EN-07/2022 19
80V70A AC380V±15% Three phase four wire 2.5mm2 16A-3p <=11A
96V60A AC380V±15% Three phase four wire 2.5mm2 16A-3p <=12A
115.2V50A AC380V±15% Three phase four wire 2.5mm2 16A-3p <=11.6A
48V200A AC380V±15% Three phase four wire 6mm2 32A-3p <=19A
115.2V100A AC380V±15% Three phase four wire 6mm2 32A-3p <=21A
153.6V70A AC380V±15% Three phase four wire 6mm2 32A-3p <=20A
115.2V150A AC380V±15% Three phase four wire 10mm2 63A-3p <=32.1A
EK22EN-07/2022 20
Chapter 5 Maintenance
Battery maintenance operations
EKT Lithium battery requires minimum maintenance.

Complete the following maintenance work on a weekly basis:
• Clean dust, metal filings and other debris from the battery system cover using
compressed air.
• Check the plugs of the battery's power line and communication line for looseness.
Recommend to do full charge based on your operation frequency.

• For heavy work condition, for example, more than 8 hours every day, doing full
charge at least once a week will help to extend the battery life.
• For normal work condition, please do full charge at least once a month.
For cold storage application, check inside of

battery tray and remove moisture regularly.
Recommend once every two months.
Inspection of the electronic system
Regular inspection of battery’s electronic system is highly recommended,

once every 3 months as following:
 Whether the high/low voltage cable of battery system is scratched
or loosened
 Whether the charging and discharging plug is damaged,
or generate abnormal heat during charging and dis-charging.
Insulating shoes, insulating gloves and safety goggles

are essential before inspection.
EK22EN-07/2022 21
Trouble shooting
 The main interface shows

under the SOC when battery faults.
 Touch the screen and select

button, enter the engineering
interface.
 The error code shows on the top of
the screen.
 Touch the error code area, enter the
faults history interface.
Monochrome LCD
 The error code will be instead of SOC, end up with

“AL”
 The position of hour meter shows the
corresponding alarmed cell serial number. If no
single cell, there will be no number shown
 In the unlikely event that multiple faults occur in
the same time, the error codes will scroll, and
maximum up to 3 codes.
EK22EN-07/2022 22
Error codes list
HEX Error Code Description Troubleshooting
0 ChgHighVolt Cell overvoltage during charging Full charge
1 DchgHighVolt Cell overvoltage during discharging Stop. Check the feedback current of truck
Caused by over discharging. Continue

2 ChgLowVolt Cell undervoltage during charging
charge
Cell undervoltage during

3 DchgLowVolt Stop. Charge the battery
discharging
System overvoltage during

4 ChgHighTotVolt Full charge
charging
System overvoltage during

5 DchgHighTotVolt Stop. Check the feedback current of truck
discharging
System undervoltage during Caused by over discharging. Continue

6 ChgLowTotVolt
charging charge
System undervoltage during

7 DchgLowTotVolt Stop. Charge the battery
discharging
Check the voltage value and cell number.

Cell voltage difference exceeds limit
A ChgDiffVolt Measure the cell and compare to the value
during charging
by BMS. Caused by cell or cable connection
Cell voltage difference exceeds limit

B DchgDiffVolt Same as above #A error
during discharging
Check the temperature value and cell

Temperature too high during number. Measure the cell and compare to
C ChgHighTemp
charging the value by BMS. Caused by environment
or cell or cable connection
EK22EN-07/2022 23
Temperature too high during
D DchgHighTemp Same process as above #C error
discharging
Temperature too low during

E ChgLowTemp Same process as above #C error
charging
Temperature too low during

F DchgLowTemp Same process as above #C error
discharging
Temperature difference exceeds

10 ChgDiffTemp Same process as above #C error
limit during charging
Temperature difference exceeds

11 DchgDiffTemp Same process as above #C error
limit during discharging
Check the charger. It should provide right

13 AcOverCur Over-current during slow charging
current according to BMS
14 FbOverCur Over-current of feedback current Check the feedback current of truck
Continuous over-current during

15 DchgConOverCur Check the operation of truck or load
discharging
Transitory over-current during

16 DchgTransOverCur Check the operation of truck or load
discharging
18 LowSoc SOC too low Stop using and charge the battery
Disconnect discharge plug and restart

battery. If no error, it’s caused by the truck
19 Insulation Insulation Fault
short circuit. If still error, by battery itself.
Please contact EIKTO service.
Check the cell voltages to find which cable.
Cell voltage communication wiring
80 VoltLine Caused by cable connection or cable broken
fault
of cell or BMS side.
Cell temperature communication

81 TempLine Same process as #80 error
wiring fault
Power off and restart battery to check error

90 RlyFault Relay fault
exists or not. If still error, replace replay.
EK22EN-07/2022 24
Monochrome LCD
Error
Error indication Troubleshooting
Code
a. Measure the voltage of battery or cells by multimeter.

01AL Cell overvoltage
b. Check the BMS communication connectors & wirings.
a. Check the SOC;

02AL Cell undervoltage b. Measure the voltage of battery or cells by multimeter.
c. Check the BMS communication connectors & wirings.
03AL System overvoltage Same as 01AL
04AL system undervoltage Same as 02AL
05AL Voltage difference exceeds limit Same as 01AL
Disconnect the truck and restart the battery, check error

06AL Discharge overcurrent occurs or not.
Check the truck circuit.
Check the charger is right model. Check the charger is

07AL Charging overcurrent
working normally.
08AL Cell temperature too high

a. Check the temperature of the battery and environment.
b. Check the temperature of cells to find abnormal.
09AL Cell temperature too low c. Check the BMS temperature communication connectors
& wirings.
Temperature difference exceeds d. Check the temperature sensors.
10AL
limit
11AL Battery SOC low Charge the battery
Disconnect the truck and restart the battery, check error

12AL Low Insulation occurs or not.
Check the truck circuit.
EK22EN-07/2022 25

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Please read the manual carefully before installing/operating our product.

Please keep this manual properly for future reference.

Neglect of manual instruction may not only damage

Benefits of LiFePO4 Battery system

Chapter 2 Safety ..............................................................................................................3

Chapter 3 Overview ......................................................................................................... 7

Chapter 4 Operation ...................................................................................................... 10

Chapter 5 Maintenance ................................................................................................. 21

Description of use and climatic conditions

• Working environment temperature -20℃--50℃

Explanation of technical terms

Full charge of the battery

Personnel qualification requirements

Do NOT short circuit positive and negative pole at any time.

Non-professionals not allowed to make maintenance.

Do NOT wear watches and other metal products during repair.

Your battery is sealed according to IP54,

Do NOT damage battery cells by penetration or throw into fire, etc.

Unusual Fire and Explosion Hazards:

General View of a typical traction battery

3 Battery tray The container of battery modules and electrical components

4 Display communication cable Display power and data cable

7 Charging plug Connected to charger during charging

Standard MSD type and customized batteries are all provided.

MSD hereby means “Minimal Standard Dimension”.

Safety matters and precautions

Battery transportation requirements

Lithium Battery is Class 9 DGR commodity, you may

Color touch screen LCD

1. The main interface displays SOC (‘100%’ in figure)

button, slide among different

 Select button, enter the

 Select button, enter to ‘Setting’

 Touch and select button, enter

 Touch and select button, enter

 Touch and select button, enter

 Touch and select button,

1. The main interface displays SOC (“80%” in figure)

Color Touch Screen Monochrome LCD

External Battery Display

 Ensure your battery is securely connected with equipment.

Charging the battery

 Ensure battery is “ON” before charging.

• Batteries should be separated from other materials and stored in a noncombustible,

Battery system shall be stored in below environment:

• Disposal of the battery should be performed by permitted, professional disposal firms

Three-phase Four wire system,

 You need to install the AC socket fittings.

Recommended requirements for AC input cables and air switch as below,

Battery maintenance operations

EKT Lithium battery requires minimum maintenance.

Recommend to do full charge based on your operation frequency.

For cold storage application, check inside of

Inspection of the electronic system

Regular inspection of battery’s electronic system is highly recommended,

Insulating shoes, insulating gloves and safety goggles

Color touch screen LCD

 The main interface shows

 Touch the screen and select

 The error code will be instead of SOC, end up with

Color touch screen LCD

HEX Error Code Description Troubleshooting

0 ChgHighVolt Cell overvoltage during charging Full charge