FLUX POWER LiFT Pack Manual de instrucciones

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Contents

LiFTPACK™BATTERYCONSTRUCTION...............................................................2

TEMPERATUREPERFORMANCE..........................................................................3

CHARGER/CHARGING.......................................................................................3

CELLCHEMISTRYANDCONSTRUCTION..............................................................5

SHIPPING&RECYCLING......................................................................................6

SAFETY................................................................................................................7

MISCELLANEOUS................................................................................................8

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FREQUENTLY

ASKED

QUESTIONS

LiFTPack™AdvancedLithiumBattery

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2FAQ

LiFTPACK™BATTERYCONSTRUCTION

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WhatistheFluxLiFTPackBatterymadefrom?

TheLiFT‐24Vpackisbuiltfromeitherlargeformatprismaticor

pouchlithium‐ioncells.Thecellsareconstrainedagainstshockand

vibrationina10gaugeA36steelenclosure.Battery

interconnectionsaremadewithflexiblebusbarsandAWG2high

strandcabling.Theschematictotherightillustratesallofthe

integralpartsofaLiFTPack.

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WhatdoestheLEDpaneltellme?

1) WhentheLightsarestatictheLEDactsasabatterydischargeindicator(BDI).

2) IfthereisasingleflashinglightitisaDeviceTroubleCode(DTC).

3) Ifthelightsarelightinginseriesitconfirmsthepackischarging.

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IsthereaBatteryDischargeIndicator(BDI)onthepack?

Yes,thereisaBDIorStateofCharge(SOC)indicatoronthepack.AseriesofLEDsindicatethebatteriesstateofchargefrom

0‐100%.Whenthepackisat5%theredLEDwillbelitasindicatedbelow,inadditionabuzzerwillsoundindicatingthepack

shouldbepluggedinforcharging.Tomaintainbatteryperformancewestronglyrecommendthepackbepluggedinatthis

point.

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WhatAreDeviceTroubleCodes(DTC)?

Ifthepackisoperatingoutsideofoperationalparameters,theBMSwillcutpowertothe

pack,andblinkasinglespecificLEDrelatedtoaDTC.Thediagramtotherightdetailsthe

DTCsassociatedwitheachlight.

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3FAQ

TEMPERATUREPERFORMANCE

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Whataretheeffectsoftemperatureoncapacityandoperationforbothhigh(120‐

140˚F)andlowtemperatures(0‐20˚F)?

Thesupporteddischargetemperaturerangeis‐4˚Fto140˚Fandsupportedchargerangeis32˚Fto140˚F.At140˚Fthe

availablecapacityis100%,at32˚Fthereis75%availablecapacity,andat‐4˚Fthereis41%availablecapacity.Constant

operationat140˚Fmayreducethebatterycyclelifetimeby10‐20%.

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Isthetemperaturerangeof‐20Cto60C(‐4Fto140F)theoperatinginternal

temperatureofthepackortheambienttemperature?

Thisistheinternaloperatingtemperature.Therearetemperaturesensorsinsidethepackwhichmonitortheoperating

temperature.Ifthetemperaturerangeisexceeded,thebuzzerwillsoundandthepackwillautomaticallyshutoffuntilthe

packisallowedtocool/heattowithinoperationalparameters.

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WhatisthetemperatureincreaseduringuseofFluxLiFTPackscomparedtoLead‐Acid?

FluxLiFTPacksexperienceminimaltemperatureincreaseduringcharginganddischarging.TestsrunbyFluxPowerindicate

floodedlead‐acidtemperaturesincrease27%moreandAGMincrease47%morethanFluxLiFTpacksduringa1hour

completedischarge.Thisisduetothelowerinternalresistanceoflithium‐ionvs.lead‐acid,andmeansthebatterywastes

lessenergywhencharginganddischarging.

CHARGER/CHARGING

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CanFluxLiFTPacks

beopportunitycharged?

Yes,FluxLiFTPackscanbepluggedinatanystateofchargewithabsolutelynonegativeeffects.Infact,opportunitycharging

canactuallyincreasethelifetimeamp‐houroutputofthebattery.Thepackdoesneedperiodicbalancinghowever,andwe

recommendleavingitpluggedinovernightorovertheweekendonceeveryweekortwo.

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Whathappenswhenthepackrunsoutofcharge?

Whenthebatteryreaches5%SOCabeeperwillsoundnotifyingtheoperatorthatthebatterymustbecharged.Oncethe

batteryreaches1%SOCthebeeperwillsoundagain,notifyingtheoperatoragain.Finallyitwillcutpowerintermittentlyand

allowthepalletjacktobeslowlydriventoachargingpoint.Werecommendpluggingthepackinassoonastheinitialbuzzer

soundstoprolongthelifeofthebattery.Ifthepackisnotpluggedinandleftsittinginanunchargedstate,itispossiblethe

lithiumcellswillbepermanentlydamagedandnolongerfunction.

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DoIneedtodisconnecttheLiFTPackfromthewalkie/palletjacktochargeit?

IftheLiFTPackhasaninternalchargeritdoesnotneedtobedisconnectedfromthewalkietochargeit.However,pleasebe

awarethatthepalletjackwillbeoperationalwhilechargingsoit’srecommendedtheAndersonpowerconnectorbe

disconnected.

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4FAQ

Ifthepackispluggedinforcharging,isthewalkie/palletjackoperational?

Yesthewalkieisoperational;unpluggingthemainAndersonpowerconnectorisrecommended.

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AtwhattemperaturescanIchargeaFluxLiFTPack?

FluxLiFTPacksshouldonlybechargedbetween32˚F‐140˚F.

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IsitOKtoleavetheLiFTPackpluggedin?

Yes,theBatteryManagementSystem(BMS)monitorschargingsothebatterywillneverovercharge.Fluxactually

recommendsleavingthechargerpluggedinatalltimeswhenthebatteryisnotinuse.

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Canyouoverchargeoroverdischargethepacks?

FluxPower’spatentedBatteryManagementSystem(BMS)monitorschargingsothatthepackcannotbeoverchargedor

discharged.Theonlypossibleriskisifsomeonefullydischargesthebatterypackandthendoesnotplugitin.Inthiscase,

becauseofthesmallparasiticdrawfromtheelectronics,itispossibletocompletelykillthepack.Thisiswhywerecommend

thepacksremainpluggedinwhenevernotinuseformorethanafewdays.Thereisnoharminleavingthepackspluggedin,

butgreatharmiftheyareleftdischargedforextendedperiodsoftime.

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WhattypeofchargerandchargingprofileisusedintheLiFTPack?

TheonboardchargerisahighfrequencyBMScontrolleddevice.Itwillchargeatconstantcurrentuntilthepackvoltage

reaches28.55Vandthenuseafloatvoltageof28.55Vtofinishchargingandbalancing.

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Canalead‐acidchargerbeusedtochargetheFluxbattery?

FluxLiFTPacksrequireahigherchargingvoltagethanlead‐acidandcomewithanonboardcharger.Howeverinsome

instancesalead‐acidchargercanbeusedtopartiallychargetheLiFTPack–butforoptimalperformance,alwaysusethe

onboardcharger.

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IsthechargerCEC(CaliforniaEnergyCommission)approved/rated?

InternalchargersareexemptfromneedingCECapproval(mobileplatform)andtheexternalchargerisexemptuntilFeb.1

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2017.

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HowmuchcurrentdoestheLiFTPackonboardchargerdraw?

Itisa775Wcharger,sothecurrentdrawisdependentonthesuppliedvoltage.Ifthesocketsupplies130V,thechargerwill

draw5.9A.Ifthewallsocketsupplies110V,thechargerwilldrawapproximately7A.StandardUSelectricaloutletssupplya

rangeofvoltagesdependingonthedistancefromthetransformer.

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Whattypeofcordisusedforcharging?

Aregular120VACextensioncordisusedforcharging.TheLiFTPackshipswitha10ftcord.Thechargerrequires105‐130Vto

functionproperly,souseawiresizingguideifyouwishtousealongerextensioncord.

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5FAQ

Atwhatdepthofdischarge(DOD)doesthebatteryexperience1cycle?

Thereisnopointatwhichadischargecountsas1cycle.Eachcycleputswearonthebatteryproportionaltoitsdepthof

discharge.Ifthebatteryisdischargedto80%everycycle,itwilllast~2000cycles.Ifthebatteryiscycledat70%DOD,the

batterywilllast~3,000cycles.

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Thishasanonlineareffectonthetotalamp‐houroutputofthebatteryoveritslifetime.ThesmallertheDODis,thelarger

thetotalAhoutputofthebatteryis.Comparingthelifetimeoutputoftwo100Ahbatteriesat80%and70%DOD,thetotal

Ahoutputcanbeidealizedbythefollowing:



100Ah*0.8DOD*2000=160,000Ahtotaloutput,

100Ah*0.7DOD*3000=210,000Ahtotaloutput.



Inrealitythetotallifetimeoutputnumberswillbeclosertogether,asfactorssuchasbatteryagingarenotbeingconsidered,

howeverthe70%DODbatterywillstilloutputmoreAhoveritslifetime.Thisisthemainreasonwhyopportunitychargingis

aperfectfitforLiFTPacks.

CELLCHEMISTRYANDCONSTRUCTION



WhattypesofLithium‐ionchemistriesareavailable,andwhydoweuseLiFePO

?

Thereareanumberofdifferentchemistriesavailable.FluxusesLiFePO

duetoitslongcyclelife,lowcostofownership,

thermalstability,andhighpoweroutput.BelowisachartwhichprovidessomeinformationonalternativeLithium‐ion

chemistries.



SpecificationsLi‐cobalt

LiCoO

(LCO)

Li‐manganese

LiMn

(LMO)

Li‐phosphate

LiFePO

(LFP)

NMC



LiNiMnCoO



Voltage3.60V3.80V3.30V3.60/3.70V

Chargelimit4.20V4.20V3.60V4.20V

Cyclelife5005002,0002,000

Operating

temperature

AverageAverageGoodGood

Specificenergy150–190Wh/kg100–135Wh/kg90–120Wh/kg140‐180Wh/kg

Loading1C10C,40Cpulse35Ccontinuous10C

SafetyAverage.AverageVerysafeSaferthanLi‐cobalt.

Thermal.runaway150°C

(302°F)

250°C

(482°F)

270°C

(518°F)

210°C

(410°F)

*BatteryUniversity



6FAQ

What“wearsout”inLithium‐ionbatteries?

Aslithiumironphosphatecellscycle,thechargeiscarriedbetweentheanodeandcathodeusinglithiumions.Asthepack

cyclesaverysmallpercentageofthemobilelithiumionsarecaughtinirreversiblesidereactions.Thisreducestheamountof

chargetransferpossiblebetweentheelectrodes.Inlead‐acidthisissomewhatanalogoustosulfation,wherethesulfur

becomeslockedinstableleadsulfitecrystalsandcannolongerintercalateintotheleadplates.Sulfationisworsehowever

asitoccursduringuseandduringstorage,thecrystalscangrowandcracktheplates,andblockelectrolyteaccesstothe

plates.



Whatistheelectrolyteinthesebatteries?

Fluxlithiumbatteriesuseanelectrolyticsaltdissolvedinorganicsolvents.



WhatisthespecificgravityofFluxlithiumbatteries?

Specificgravityisnotrelevantforlithiumbatteries.Generally,specificgravityisusedtomeasurethedensityoflead‐acid

electrolyteagainstwater.Lithiumbatteriesaresealedandmaintenancefree,sothereisnowaytomeasuretheelectrolyte

andnowaterisused.



Whatarethepositiveandnegativeactivematerials?

Thecathode(positiveelectrode)islithiumironphosphatewithacopperchargecollector,andtheanode(negativeelectrode)

isgraphitewithintercalatedmetalliclithium,andanaluminumchargecollector.



WhatdoesIntercalatemean?

Intercalationistheinsertionoflithiumionsintotheanodeandcathodematerial.



WhatarethechemicalreactionsoccurringwithinaFluxlithiumbattery?

Whenthebatterycharges,thelithiumionsareinthecarbon/graphiteanode,andwhendischargingthelithiumionsmoveto

thecathode.Thechemicalreactionsareasfollows:

•Charge:LixC6=6C+xLi+xe

•Discharge:Li(1‐x)FePO4+xLi+xe=LiFePO





Doesthelithiumbatterypackhaveapositiveandnegativegridlikelead‐acidbatteries?

Lead‐acidusesaleadplate,andaleaddioxidepastethatmustbesupportedbyastructuralgridastheiranodeandcathode.

Fluxlithiumbatterieshaveananodeandcathode,butnogridisusedasthereisnoleaddioxidepaste.

SHIPPING&RECYCLING



WhatdoIneedtoknowtoshipaLiFTPack?

Similartolead‐acid,therearepackaginginstructionswhichmustbefollowedwhenshipping.ALiFTPackmustbeshippedin

accordancewithUN3480,HazardClass9,packaginggroupII,instruction965.Ifthepackisshippedinequipment,use

packaginginstructions967.IfyouneedfurtherassistancepleasecontactyourFLUXPowerrepresentative.



7FAQ

Whatdoyoudowiththebatteriesattheendoftheirlife?Istherearecycling

program?

Recyclingmethodsarecurrentlybeingdeveloped,withreportsof60%recyclabilityatthecelllevel.Lithiumbatteriesarethe

futureofenergystorage,andrecyclingefficienciesarepredictedtoclimbto>90%asthemarketsscaleandadditional

recyclingmethodsaredeveloped.Untilamaturerecyclingprogramisavailable,FluxPoweragreestotakebackanybattery

attheendofitsusablelifeforeitherrecyclingorrepurposing.Alsonote,becauselithiumbatterieshaveamuchlongerlife‐

timevs.lead‐acid,therewillbedramaticallyfewerbatteriessubjecttorecyclingovertime.Ifyourequiremoredetailed

informationregardingrecycling,pleasecontactyourFLUXPowerrepresentative.

SAFETY



Whathaveyoudonetoverifythepackwillphysicallylast5years?

ThepackisdesignedtomeetUL583.WehavedonethemoreabusiveshocktestingrequiredforUL2580andpassed.



AreFluxlithiumbatteriessafe?

ThereareanumberoffactorsresponsiblefortheremarkablesafetyofFluxlithiumbatteries.

1) Theselectionofbatterychemistryisimportant.ThereareanumberofLithium‐ionchemistriestochoosefrom,and

eachhasuniqueproperties.Fluxhaschosenlithiumironphosphate(LiFePO

)foranumberofreasons.Most

importantlyLiFePO

ischemicallystableandhasthehighestthermalrunawaytemperatureofanylithium‐ion

chemistryat518˚F.Thenewsstoriesofcellphoneandlaptopbatteriescatchingfirewereacobaltbasedchemistry

thatislesschemicallystable.Thesebatteriesarealsoinasmallcylindricalcellformat.

2) Thelithiumcellsusedareintheformoflargepouchandprismaticcelltechnologyversuscylindricalcell.Thepouch

andprismaticcellscontain>20Ahversusthe2.5Ahincylindrical,meaningLiFTPackbatterieshaveupto10times

fewerpowerconnections.Inadditionthecellsareconnectedwithflexiblebusbars,meaningtheyareextremely

vibrationresistant.

3) TheuseofLargeFormatCellsmeanstherearefarfewercelltapsandtemperaturesensors.Thissystemisless

complexandinherentlysafer.

4) TheBMSmonitorsthecelltemperatureandcurrentandshutsthesystemdownifitdetectsanythingwhichmay

causeharmtothebattery.Thisistomaintainbatteryperformanceandexpectedlifetime.



Whathappensifthepackisbreached,whatleaksoutandisitdangerous?

Thelithiumcellsarefirstencasedinhardplastic,andthenanindustrial10gaugeA36powdercoatedsteelcase.Ifauser

puncturesthroughallofthesematerialsandexposesthelithiumcellelectrodesandelectrolyte,becautiouswhenhandling.

Theelectrolyteconsistsoforganicsolvents(EC,PC,DEC)andadissolvedelectrolyticsalt(LiPF

).Theyareskinandeye

irritants,andfumescancausemucusmembraneirritation.Thesolventsareflammablesodonotexposetoanopenflame.

Userubbergloves,eyeprotection,ventilationandpositivepressurebreathingprotectionwhenremovingthedamaged

batteryandelectrolyte.Inaddition,LiPF

ishydrophilicandreactswithwaterreleasinghydrogenfluoride,acorrosive

flammablegas.Ifafiredoesoccur,useaCO2orchemicalfireextinguisher.



Willthebatteriescatchfire?

FluxPoweruseslithiumironphosphateinitsproductsasitisthemoststablechemistry.Theburntemperatureisover500˚F,

muchhigherthanotherchemistriessuchaslithiumcobaltat300˚F.Thechemicalstabilityalsoprovideslongcyclelifetimes



8FAQ

(2000at80%DOD).Inadditiontherearesafetymeasuresbuiltintothepackwhichpreventoverchargingandrapid

discharging.Finallythebatterycaseismadeofhighgradesteel,protectingthecellsfromdamage,andcontainingthem

shouldacellbreachoccur.Alloftheseprotectionsmeanthatundernormalusagethereisnodangerofafire.Thedangers

ofspillsandexplosivegasbuildupfromlead‐acidbatteriesaremuchmorecommonthanaLiFTPackcatchingfire.

MISCELLANEOUS



Whathappenswhenasinglecellfailsinalead‐acidbatteryvs.aFluxlithiumbattery?

Lead‐acid:

Whenasinglecellfails,thereisnoBMStomanagethecharging.Thereforethefailingcellwillheatup,butnotfullycharge.

Thefailingcellwillaccelerateitsdeclineasitisusedimproperlyandcausetheentirepacktodrainrapidlywheninuse.Asan

example,ifafailinglead‐acidcellisat50%capacity,thechargerwillnotattempttochargeittoitsfull(diminished)capacity,

thismeansthatoncethepackisused,thevoltagedropwillbesignificantinthiscell,andtheentirepackwillseeadrastic

dropinrun‐timeduetothelowvoltageinthiscell.



Fluxlithiumbattery:

Whenasinglecellbeingstofail,theentirepackwillexperienceareductionofrun‐timeproportionaltothesinglefailingcell’s

reductioninruntime.TheBMSwillstillchargeandbalancethecells,butthepackwillcutoffwhenthefailingcellvoltage

dropsto2.8Volts.Asanexample,ifthefailingcellisat50%capacity,thechargerwillstillchargethecelltofull(diminished)

capacityandthecellwillproducetheexpectedvoltage,justfor50%shorterrun‐time.Thepackwillthenrunasifithas50%

capacity.TheBMSwillprotecttheothercellsfromharmduetoalowcell.Inessence,theBMSavoidsthelowvoltage

scenariowhichisproblematicinlead‐acid.



Howdoesadealerdiagnoseabatteryshouldanissuearise?

TheStateofChargeindicatorlightsalsodisplayDiagnosticTroubleCodes(DTCs)whicharedetailedintheQuickStartGuide

andthisFAQ.IfforsomereasontheproblemcannotbedeterminedusingtheDTCs,Fluxwillprovidecommunicationcables

andsoftwaretoconnecttothepackforamoredetailedinspectionoftheissue.Theonboardfirmwareprovidesdetailed

reportsofallcellandpackbehavior,makingdiagnosisofaproblemquickandeasy.



WhydoestheFluxproductspecificationsheetshowavoltagehigherthan24V?

Lithiumcellshaveahighernominalvoltagethanlead‐acid.TheFluxLiFTpackiscomprisedof8Lithiumcellsconnectedin

series,eachwithanominalvoltageof3.2V.Thepacknominalvoltageistherefore25.6V.Thereisminimalvoltagedropas

thepackdischarges,andundernormaluse,thepackwillindicateitneedstobechargedwhenitdropsto~23‐24V.



DoLiFTPacksrequireperiodicmaintenance?

No,butanannualinspectionisrecommendedbyanauthorizeddealertoensuremaximumbatterylife.



Howcanweoffera5‐yearwarranty?

BasedonaverageusageprofilesandFluxlithiumbatterypackslasting2000cycles,FluxexpectstheLiFTPackstolast7years

beforetheyareat80%oftheiroriginalcapacity.Ifanenduserisrunningthepack24/7andcyclingthepack3timesina24

hourperiod,theremaybeadditionaldecreasedcapacityafterthe5yearmark,butthepackwillstillfunctionasintended.



FLUXPowerInc.

985PoinsettiaAve.

www.FLUXpwr.com



VistaCA,92081

877‐505‐3589

FluxPowerisaregisteredtrademarkofFluxPowerInc.990821v1.1

Tabla de contenidos

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FLUX POWER LiFT Pack X48 Manual de usuario

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FLUX POWER LiFT Pack X80 Manual de usuario

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FLUX POWER LiFT Pack M36 Manual de usuario

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