Still X-Line Original Instructions Manual
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Still X-Line Original Instructions Manual

Still X-Line Original Instructions Manual

Lithium-ion batteries
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Original instructions
Lithium-ion batteries
X-Line/C-Line
50988012301 EN - 05/2023  -  04

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Summary of Contents for Still X-Line

  • Page 1 Original instructions Lithium-ion batteries X-Line/C-Line 50988012301 EN - 05/2023  -  04...
  • Page 3 Preface   Manufacturer and contact de- tails STILL GmbH Berzeliusstrasse 10 22113 Hamburg, Germany Telephone: +49 (0) 40 7339-0 Fax: +49 (0) 40 7339-1622 Email: Info@still.de Website: www.still.de 50988012301 EN - 05/2023  -  04  I...

  • Page 5: Table Of Contents

    Table of contents   Foreword   Before using the battery.......... 2 Important information about these instructions .
  • Page 6 Table of contents   Battery group 9 ............ 34 Battery group 11 .
  • Page 7 Table of contents   Technical data   Datasheet for lithium-ion batteries ........ 64 Temperature ranges for lithium-ion batteries.

  • Page 9: Foreword

    Foreword...

  • Page 10: Before Using The Battery

    Foreword Before using the battery Before using the battery  DANGER Failure to observe the safety informa- tion poses a risk of fatal injury! Failure to observe the safety information can result in electric shock, burns, seri- ous injury or death. –...
  • Page 11 Foreword Important information about these instructions Storing these instructions To ensure safe use, these instructions must be accessible to all users. – Always store these instructions in the vicini- ty of the battery. – Notify all battery users of the storage loca- tion for these instructions.

  • Page 12: Intended Use

    Charge the battery only with battery chargers approved by the manufacturer. Use the battery (X-Line / C-Line) only in ac- cordance with the approved ambient condi- tions, see the chapter entitled "Ambient condi- tions".

  • Page 13: Dangerous Incorrect Use

    Never use the battery in areas where there ● is a risk of fire or a risk of explosion. Do not climb on the battery. ● Use the battery (X-Line / C-Line) only in ● accordance with the approved ambient con- ditions, see the chapter entitled "Ambient conditions".

  • Page 14: Product-Specific Dangers

    Foreword Product-specific dangers Short circuit A short circuit can destroy the battery and start a fire. Do not short circuit the battery. ● Keep the contacts away from metallic ob- ● jects. Misuse Misuse can destroy the battery and result in personal injury or property damage.

  • Page 15: Compliance Information For Lithium-Ion Batteries

    Foreword Compliance Information for lithium-ion batteries The latter can cause ventricular fibrillation, cardiac arrest or respiratory paralysis, leading to death. Improper handling can arc faults and subse- quently lead to burns. If a battery combusts, the resulting smoke or vapours can cause irritation of the eyes, skin and respiratory system.

  • Page 16: Explanation Of Signal Terms Used

    Foreword Explanation of signal terms used Explanation of signal terms used  DANGER Indicates procedures that must be strictly adhered to in order to prevent the risk of fatalities.  WARNING Indicates procedures that must be strictly adhered to in order to prevent the risk of injuries.  CAUTION Indicates procedures that must be strictly adhered to in order to prevent material damage and/or destruc-...
  • Page 17 Foreword Explanation of signs and symbols Not to be maintained by the user  Do not climb  Do not lift using a triangle cable guide  Use a lifting traverse  Do not burn the battery  – Do not stack batteries ...

  • Page 18: User Qualifications

    Foreword User qualifications The product contains recyclable materials  User qualifications The battery must only be used by adults. Users must not have any physical or mental disabilities that reduce their capacity to recog- nise hazards and to intervene in dangerous situations.
  • Page 19 Foreword Danger area X-Line The temperature of the brake resistor in the battery can rise to over 100°C during opera- tion. The surface of the battery in this area can also become very hot. It can take several hours for the components to cool down to a temperature at which they pose no risk.

  • Page 20: Ambient Conditions

    Observe the instructions for using the bat- ● tery in the operating instructions of the in- dustrial truck. X-Line Permissible temperature ranges See the chapter entitled "Technical data" for the relevant bat- (operation, charging, storage) tery group. Protection class rating IP6K9K Moisture/humidity The battery can be used both outside and in buildings.

  • Page 21: Identifying The Battery

    Foreword Identifying the battery Identifying the battery Nameplate The individual battery is identified by the serial number (9). The battery type can be identified using the "Installed energy" (11) information or the bat- tery group (see chapter entitled "Battery-Part- Number (B-P/N)"). Overview ...
  • Page 22 03   Manufactured in 2017 S   Series 199   Day 199 of 2017 0402   Battery group 4.2 S   Produced for STILL 01   Production number 01 of battery group 4.2 on day 199  14 50988012301 EN - 05/2023  -  04...

  • Page 23: Safety

    Safety...

  • Page 24: Battery Management System And Safety

    Protection against incorrect charging ● Protection against polarity reversal ● Voltage monitoring for each cell ● Circuit break devices in each module ● Safety valve on each cell (X-Line only) ● Cell temperature monitoring ● Temperature monitoring for the battery ● electronics  16...

  • Page 25: Information In The Event Of Emergency

    – Do not inhale toxic fumes. Battery is becoming dispropor- tionately hot and reporting an er- X-Line If the battery displays an error and becomes disproportionately hot (over 80°C): Contact the authorised service centre im- ●...

  • Page 26: Gas Escaping From The Battery

    Safety Information in the event of emergency Gas escaping from the battery  DANGER Risk of poisoning due to vapours Inhaling vapours may cause poisoning. – Call the fire brigade. – Position yourself on the side of the fire from which the wind is blowing. –...

  • Page 27: First-Aid Measures

    Safety First-aid measures First-aid measures Course of action required if gases or liquids escape Inhalation Escaping gases can lead to breathing difficul- ties. – Ventilate the area immediately or seek fresh air. – Always contact a doctor. Skin contact Skin irritation can occur in the event of contact with the skin.
  • Page 28 Safety First-aid measures  20 50988012301 EN - 05/2023  -  04...

  • Page 29: Overviews

    Overviews...

  • Page 30: Battery Group 1

    Overviews Battery group 1 Battery group 1 X-Line Battery male connector Technology compartment Lifting eye Diagnostic connector Display  Area which could be heated by the brake resistor  22 50988012301 EN - 05/2023  -  04...

  • Page 31: Battery Group 2

    Overviews Battery group 2 Battery group 2 X-Line 2.x Battery male connector Technology compartment Lifting eye Diagnostic connector Display  Area which could be heated by the brake resistor 50988012301 EN - 05/2023  -  04  23...
  • Page 32 Overviews Battery group 2 X-Line (2.1 only) Battery male connector  Area which could be heated by the brake Lifting eye resistor Display Diagnostic connector Technology compartment  24 50988012301 EN - 05/2023  -  04...
  • Page 33 Overviews Battery group 2 C-Line Battery male connector Diagnostic connector Lifting eye Technology compartment 50988012301 EN - 05/2023  -  04  25...

  • Page 34: Battery Group 3

    Overviews Battery group 3 Battery group 3 X-Line Battery male connector Technology compartment Lifting eye Diagnostic connector Display  Area which could be heated by the brake resistor  26 50988012301 EN - 05/2023  -  04...
  • Page 35 Overviews Battery group 3 C-Line Battery male connector Diagnostic connector Lifting eye Technology compartment 50988012301 EN - 05/2023  -  04  27...

  • Page 36: Battery Group

    Overviews Battery group 4 Battery group 4 X-Line 4.x Battery male connector  Area which could be heated by the brake Lifting eye resistor Display Diagnostic connector Technology compartment  28 50988012301 EN - 05/2023  -  04...
  • Page 37 Overviews Battery group 4 X-Line (4.1 only) Battery male connector  Area which could be heated by the brake Lifting eye resistor Diagnostic connector Display Technology compartment 50988012301 EN - 05/2023  -  04  29...

  • Page 38: Battery Group 5

    Overviews Battery group 5 Battery group 5 X-Line Battery male connector Technology compartment Lifting eye Diagnostic connector Display  Area which could be heated by the brake resistor  30 50988012301 EN - 05/2023  -  04...

  • Page 39: Battery Group 6

    Overviews Battery group 6 Battery group 6 X-Line Battery male connector Technology compartment Lifting eye Diagnostic connector Display  Area which could be heated by the brake resistor 50988012301 EN - 05/2023  -  04  31...

  • Page 40: Battery Group 7

    Overviews Battery group 7 Battery group 7 X-Line Battery male connector Technology compartment Lifting eye Diagnostic connector Display  Area which could be heated by the brake resistor  32 50988012301 EN - 05/2023  -  04...

  • Page 41: Battery Group 8

    Overviews Battery group 8 Battery group 8 X-Line Battery male connector Diagnostic connector Lifting eye  Area that could be heated by the brake Display resistor Technology compartment 50988012301 EN - 05/2023  -  04  33...

  • Page 42: Battery Group 9

    Overviews Battery group 9 Battery group 9 X-Line Battery male connector Technology compartment Lifting eye Diagnostic connector Display  Area which could be heated by the brake resistor  34 50988012301 EN - 05/2023  -  04...

  • Page 43: Battery Group 11

    Overviews Battery group 11 Battery group 11 X-Line Battery male connector Technology compartment Lifting eye Diagnostic connector Display  Area which could be heated by the brake resistor 50988012301 EN - 05/2023  -  04  35...

  • Page 44: Battery Group 13

    Overviews Battery group 13 Battery group 13 X-Line Battery male connector  Area which could be heated by the brake Lifting eye resistor Diagnostic connector Display Technology compartment  36 50988012301 EN - 05/2023  -  04...

  • Page 45: Battery Group 14

    Overviews Battery group 14 Battery group 14 X-Line Battery male connector  Area which could be heated by the brake Lifting eye resistor Display Diagnostic connector Technology compartment 50988012301 EN - 05/2023  -  04  37...
  • Page 46 Overviews Battery group 14 C-Line Battery male connector Diagnostic connector Lifting eye Technology compartment  38 50988012301 EN - 05/2023  -  04...

  • Page 47: Battery Group 15

    Overviews Battery group 15 Battery group 15 X-Line Battery male connector  Area which could be heated by the brake Lifting eye resistor Display Diagnostic connector Technology compartment 50988012301 EN - 05/2023  -  04  39...
  • Page 48 Overviews Battery group 15  40 50988012301 EN - 05/2023  -  04...

  • Page 49: Operation

    Operation...

  • Page 50: Description Of The Battery

    Operation Description of the battery Description of the battery The lithium-ion battery is an electrochemical energy storage device for powering industrial trucks. The battery is only functional once installed in the relevant industrial truck model or once connected to a corresponding lithium-ion bat- tery charger.

  • Page 51: Connecting The Battery To The Industrial Truck

    Operation Connecting the battery to the industrial truck The battery has been de-energised by the manufacturer for transportation purposes. There is no voltage at the battery terminals and the battery male connector. When connected to the truck or a battery charger, the battery switches to the operating status.
  • Page 52 Operation Modes of operation Switching on the battery The battery is switched on via a signal from the industrial truck or the battery charger. Emergency operation Medium-severity fault If a medium-severity fault is detected, the bat- tery switches to emergency operation. Battery power is limited.

  • Page 53: Charging The Battery

    Displaying the charge state  (X-Line) X-Line batteries have their own display that shows information about the condition of the battery. The display is located on the side of the battery tray. The signals from the display are described in the operating instructions of the industrial truck.

  • Page 54: Charging The Battery

    Operation Charging the battery the industrial truck and the industrial truck is switched on. NOTE If the charge state is less than 10%, charge the battery. Charging the battery The battery can be charged either when in- stalled in an industrial truck or separately if removed from the industrial truck.

  • Page 55: Switching Off The Battery

    Operation Switching off the battery NOTE The battery has no memory effect. For this reason, the battery can be charged in any charge state without the nominal capacity of the battery being impaired. At ambient temperatures below 0°C, the ● charging process will take much longer.

  • Page 56: Correcting Battery Faults

    If no error is displayed, too little power restart the industrial truck after ten seconds. The battery still does not work Contact the authorised service centre NOTE There are no parts in or on the battery that must be maintained or replaced by the user.

  • Page 57: Transporting The Lithium-Ion Battery

    Operation Transporting the lithium-ion battery Transporting the lithium-ion battery General All lithium-ion batteries are safe when used for their intended purpose. In principle, they do have the potential to cause a fire, explosion or chemical irritation. Safety information for transport- ing the battery outside the indus- trial truck All lithium-ion batteries are classified as haz-...

  • Page 58: Safety Information For Transporting The Industrial Truck With A Built-In Battery

    Operation Transporting the lithium-ion battery NOTE The current country-specific specifications and regulations must be observed when transport- ing lithium-ion batteries in and outside of an industrial truck. The Carriage of Hazardous Goods Act, the Ordinance on the Transport of Dangerous Goods and the ADR regulations set out specific requirements that apply to the dispatcher's client, the dispatcher, the packer, the loading agent, the carrier, the driver, the...

  • Page 59: Detecting Potential Damage To The Battery

    Operation Transporting the lithium-ion battery Detecting potential damage to the battery The battery is considered damaged in the fol- lowing scenarios: The battery cover shows damage that could ● impair the leak tightness of the battery The battery housing is severely damaged ●...
  • Page 60 Operation Transporting the lithium-ion battery  52 50988012301 EN - 05/2023  -  04...

  • Page 61: Maintenance

    Maintenance...

  • Page 62: Maintaining The Battery

    Maintenance Maintaining the battery Maintaining the battery Maintaining the operational readiness of the battery Performing the maintenance tasks listed here will increase the service life of the battery. This will help to maintain the operational readi- ness of the battery. The frequency of the work must correspond to the application conditions.

  • Page 63: Maintenance And Inspection Checklist

    Maintenance Cleaning the battery Maintenance and inspection checklist Carried At operating hours   1000   Jährlich                     Battery     Visually inspect the item for damage     Carry out an isolation measurement  ...
  • Page 64 Free of hydrocarbons such as CHCs, ● CFCs, aromatics, PCBs, PCTs and other pollutants. X-Line If the outside of the battery is very dirty, a high-pressure cleaner can be used with great care. The high-pressure cleaner may be used only with water without any chemical clean- ing additives.

  • Page 65: Transporting And Storing The Battery On Company Premises

    Maintenance Transporting and storing the battery on company premises Transporting and storing the battery on company premises Safety regulations Observe the operating instructions for the in- dustrial truck when removing the battery. Visual inspection before lifting Before lifting the battery, check on the outside of the battery that: All components are present ●...

  • Page 66: Storage Conditions

    Maintenance Transporting and storing the battery on company premises Observe the maximum tilt for the lifting eyes.  BMZ-0009 Storage conditions Battery charge state – Charge the battery before storage. – Keep the charge state of stored batteries above 50%. –...
  • Page 67 Transporting and storing the battery on company premises Floor load capacity Take the battery weight and the floor load ca- pacity into consideration. X-Line storage environment – Only store the battery within the permissible temperature range; see temperature ranges in the chapter entitled "Technical data" for the respective battery group.
  • Page 68 Maintenance Transporting and storing the battery on company premises – Cover the battery so that it is impervious to liquids. – The battery must not be charged any more. Do not continue to use the battery in the industrial truck. –...

  • Page 69: Disposing Of The Battery

    Maintenance Disposing of the battery Disposing of the battery Statutory provisions regarding safety The user is legally obliged to return used batteries. Returning the batteries is free of charge. If lithium-ion batteries are not dis- posed of correctly, damage to health may oc- cur due to fire or hazardous substances es- caping.
  • Page 70 Maintenance Disposing of the battery  62 50988012301 EN - 05/2023  -  04...
  • Page 71 Technical data...
  • Page 72 The capacity (kWh) specified for the batteries is the minimum level. The actual capacity of the battery may be higher. Battery group 1 Installed Available Battery group Weight (kg) Dimension (mm) Energy (kWh) Energy (kWh) X-Line 830 / 522 / 13.1 12.0 803 / 522 / 39.2 36.1 803 / 522 / 26.1 24.0 803 / 522 / 17.2...
  • Page 73 Technical data Datasheet for lithium-ion batteries Battery group 2 Installed Available Battery group Weight (kg) Dimension (mm) Energy (kWh) Energy (kWh) X-Line 1030 / 529 / 13.1 12.0 1030 / 529 / 13.1 12.0 1030 / 529 / 49.0 45.1 1030 / 529 / 26.1 24.0 1030 / 529 / 17.2 13.7 1030 / 529 / 28.6 22.9 1030 / 529 /...
  • Page 74 Technical data Datasheet for lithium-ion batteries Battery group 3 Installed Available Battery group Weight (kg) Dimension (mm) Energy (kWh) Energy (kWh) X-Line 830 / 630 / 16.3 15.0 830 / 630 / 45.7 42.1 830 / 630 / 26.1 24.0 830 / 630 / 17.2 13.7 830 / 630 / 28.6 22.9 830 / 630 / 51.4 41.2 830 / 630 /...
  • Page 75 Technical data Datasheet for lithium-ion batteries Battery group 4 Installed Available Battery group Weight (kg) Dimension (mm) Energy (kWh) Energy (kWh) X-Line 1223 / 283 / 1223 / 355 / 39.2 36.1 1223 / 385 / 39.2 36.1 1119 1223 / 385 / 26.1 24.0 1119 50988012301 EN - 05/2023  -  04  67...
  • Page 76 Technical data Datasheet for lithium-ion batteries Battery group 5 Installed Available Battery group Weight (kg) Dimension (mm) Energy (kWh) Energy (kWh) X-Line 1028 / 708 / 24.1 22.2 1210 1028 / 708 / 60.3 55.6 1210 1028 / 708 / 83.0 76.4 1210 1028 / 708 / 42.2 38.8 1210 1028 / 708 / 31.5 25.4...
  • Page 77 Technical data Datasheet for lithium-ion batteries Battery group 6 Installed Available Battery group Weight (kg) Dimension (mm) Energy (kWh) Energy (kWh) X-Line 1028 / 711 / 24.1 22.2 1558 1028 / 711 / 60.3 55.5 1558 1028 / 711 / 83.0 76.4 1558 1028 / 711 / 42.2 38.8 1558 1028 / 711 / 31.5 25.4...
  • Page 78 Technical data Datasheet for lithium-ion batteries Battery group 7 Installed Available Battery group Weight (kg) Dimension (mm) Energy (kWh) Energy (kWh) X-Line 1028 / 999 / 7.1  36.2 33.3 2178 1028 / 999 / 7.2  116.2 106.9 2178 1028 / 999 / 2) 3) 7.2  116.2 95.3 2178 1028 / 999 / 7.3 ...
  • Page 79 Technical data Datasheet for lithium-ion batteries Battery group 8 Installed Available Battery group Weight (kg) Dimension (mm) Energy (kWh) Energy (kWh) X-Line 830 / 630 / 16.3 15.0 830 / 630 / 45.7 42.1 830 / 630 / 26.1 24.0 Battery group 9 Installed Available Battery group Weight (kg)
  • Page 80 Technical data Datasheet for lithium-ion batteries Battery group 10 Installed Available Battery group Weight (kg) Dimension (mm) Energy (kWh) Energy (kWh) X-Line 1028 / 852 / 10.7 126.8 101.5 1458 1028 / 852 / 1) 2) 10.12  65.9 59.4 1458 1028 / 852 / 1) 2) 10.13  98.9 89.0 1458 The temperature range for use and the usable energy may be restricted depending on the use of the industrial truck.
  • Page 81 Technical data Datasheet for lithium-ion batteries Battery group 13 Installed Available Battery group Weight (kg) Dimension (mm) Energy (kWh) Energy (kWh) X-Line 1223 / 283 / 13.1 17.2 13.7 1223 / 283 / 1) 2) 13.11  13.2 11.9 The temperature range for use and the usable energy may be restricted depending on the use of the industrial truck.
  • Page 82 Technical data Datasheet for lithium-ion batteries Battery group 15 Installed Available Battery group Weight (kg) Dimension (mm) Energy (kWh) Energy (kWh) X-Line 1223 / 385 / 15.1 28.6 22.9 1119 1223 / 385 / 15.2 40.1 32.1 1119 1223 / 385 / 1) 2) 15.11  26.5 23.8 1119 1223 / 385 / 1) 2) 15.12 ...
  • Page 83 "Identifying the Battery". Battery group 1 Temperature ranges Installed Battery group Energy (kWh) Operation Charging Storage X-Line 13.1 -28°C - +45°C -25°C - +45°C -35°C - +60°C 39.2 -28°C - +45°C -25°C - +45°C -35°C - +60°C 26.1 -28°C - +45°C...
  • Page 84 Temperature ranges for lithium-ion batteries Battery group 2 Temperature ranges Installed Battery group Energy (kWh) Operation Charging Storage X-Line 13.1 -28°C - +45°C -25°C - +45°C -35°C - +60°C 13.1 -28°C - +45°C -25°C - +45°C -35°C - +60°C 49.0 -28°C - +45°C...
  • Page 85 Temperature ranges for lithium-ion batteries Battery group 3 Temperature ranges Installed Battery group Energy (kWh) Operation Charging Storage X-Line 16.3 -28°C - +45°C -25°C - +45°C -35°C - +60°C 45.7 -28°C - +45°C -25°C - +45°C -35°C - +60°C 26.1 -28°C - +45°C...
  • Page 86 Temperature ranges for lithium-ion batteries Battery group 5 Temperature ranges Installed Battery group Energy (kWh) Operation Charging Storage X-Line 24.1 -28°C - +45°C -25°C - +45°C -35°C - +60°C 60.3 -28°C - +45°C -25°C - +45°C -35°C - +60°C 83.0 -28°C - +45°C...
  • Page 87 Temperature ranges for lithium-ion batteries Battery group 6 Temperature ranges Installed Battery group Energy (kWh) Operation Charging Storage X-Line 24.1 -28°C - +45°C -25°C - +45°C -35°C - +60°C 60.3 -28°C - +45°C -25°C - +45°C -35°C - +60°C 83.0 -28°C - +45°C...
  • Page 88 Temperature ranges for lithium-ion batteries Battery group 7 Temperature ranges Installed Battery group Energy (kWh) Operation Charging Storage X-Line 36.2 -28°C - +45°C -25°C - +45°C -35°C - +60°C 116.2 -28°C - +45°C -25°C - +45°C -35°C - +60°C 116.2 -28°C - +45°C...
  • Page 89 Temperature ranges for lithium-ion batteries Battery group 9 Temperature ranges Installed Battery group Energy (kWh) Operation Charging Storage X-Line 16.3 -28°C - +45°C -25°C - +45°C -35°C - +60°C 49.0 -28°C - +45°C -25°C - +45°C -35°C - +60°C 26.1 -28°C - +45°C...
  • Page 90 Technical data Temperature ranges for lithium-ion batteries Battery group 11 Temperature ranges Installed Battery group Energy (kWh) Operation Charging Storage X-Line 11.6 42.3 -28°C - +45°C -25°C - +45°C -35°C - +60°C 1) 2) 11.12 33.0 -10°C - +45°C  -10°C - +45°C ...
  • Page 91 Technical data Temperature ranges for lithium-ion batteries Battery group 14 Temperature ranges Installed Battery group Energy (kWh) Operation Charging Storage X-Line 14.1 28.6 -28°C - +45°C -25°C - +45°C -35°C - +60°C 14.2 40.1 -28°C - +45°C -25°C - +45°C -35°C - +60°C...
  • Page 92 Technical data Temperature ranges for lithium-ion batteries  84 50988012301 EN - 05/2023  -  04...
  • Page 93 Index   Modes of operation....Ambient conditions....Nameplate.
  • Page 94 Index   Signal terms......8 Transporting by crane....Statutory provisions regarding safety.
  • Page 96 STILL GmbH 50988012301 EN - 05/2023  -  04...

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