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8.3.7 Charging Errors
Incorrect setup or damage to components can result in a battery not
charging or charging incorrectly. When connecting a Deka Ready Power
battery to an approved charger, ensure that it begins communicating
with the charger and charge current ramps up to charger nameplate
values before walking away. In most case this will take place within 30
seconds of connecting to the charger. If the charger does NOT supply
current or the current rate is less than expected, check the following
items:
1. Charger and battery are powered on and do not have any active faults
2. Battery and charger cables are pressed firmly together
3. Ensure there are no disconnected or damaged communication cables
on the top of the battery
4. If the battery has dual charge connectors, ensure both battery cables
are connected to the charger's dual connectors
5. If able, verify the baud rate on the battery and charge match
If none of these items remedy the problem, contact a local Deka
service representative for assistance.
8.4 Fault Detection
The Battery Management System (BMS) is an onboard computer that
monitors user inputs and sensors throughout the battery to allow max-
imum product functionality while maintaining a high level of safety. In
the event the battery experiences a condition which requires it to shut
down for safety or product protection, it will do so in one of two ways,
depending on the severity of the fault:
1. Early Warning Shutdown (EWS); If a low severity fault is detected
by the BMS, the battery will begin a countdown accompanied by au-
dible alarm (alarm is depending on system configuration). This allows
the operator to bring the fork truck to a safe or safer state before the
battery powers off.
An example of an EWS fault is a low state of charge shutdown, where
the battery powers off to prevent over-discharge.
2. Emergency Power Off (EPO); If a high severity fault is detected, an
immediate shutdown of the battery will occur. There is no countdown
in this event and power to the fork truck will cease immediately.
An example of an EPO fault is a battery being over charged by a dam-
aged charger. Once the battery detected it was being overcharged, the
BMS would command the battery to shut down immediately to prevent
product damage.
With either shutdown mode, the BMS generates Diagnostic Trouble
Codes (DTCs) to convey the reason for the shutdown. These DTCs can
be used to analyze and resolve the issue or assist with troubleshooting
efforts. The way the DTCs are presented to the user depends on the
accessories equipped with the battery.
8.4.1 UIM
If a fault occurs requiring an EWS
shutdown, a warning message will
display on the UIM screen showing the
time remaining in seconds until battery
shutdown as shown in the photo to the
right. The countdown will be accom-
panied by an audible alarm, alerting
the user to the imminent battery power
down. After the battery has shutdown,
the UIM screen will remain powered
on, but the alarm will cease.
Use the left or right arrow keys on
the front of the UIM to scroll to the
Diagnostics page where a list of all active faults will be displayed. Use
the up or down arrows to see more codes if necessary. User com-
manded shutdowns or pressing the on/off button, will not be followed
by an alarm, and the screen will power off after the countdown.
To reset from the fault condition, press the power button on the UIM to
reset the battery. Any DTCs that were displayed on the Diagnostic page
will no longer be visible after the restart. It is suggested that prior to
restarting, the operator note the DTCs or take a picture of the screen to
provide to a service technician later. If this occurs, a technician's com-
puter will be required to connect to the battery and download the DTCs
that were generated.
8.4.2 BDI
If a fault occurs requiring a shutdown, a red LED (BDI 1.0) or all of the
currently lit LEDs (BDI 2.0) on the face of the BDI will begin flashing
rapidly accompanied by an audible alarm. The alarm will cease when
the battery has shutdown. DTCs cannot be displayed on the BDI but
any DTCs generated from the fault condition will be stored in the bat-
tery management system. A technician's computer will be required to
connect to the battery and download the DTCs that were generated.
To reset from a fault condition, press the power button on the BDI to
restart the battery.
8.4.3 CAN Integrated Trucks
If a fault occurs requiring a shutdown, the
forklift truck's display will flash a warn-
ing symbol along with a 3-digit number.
There is no audible alarm associated with
this; most trucks will begin slowing down
and prevent the forks from being raised.
Consult the appropriate forklift dealer for
more information.
The 3-digit number on the lift equipment's
display represents the DTCs generated
at the time of the fault. It is suggested
that the operator note the code or take a
picture of the screen to provide to a service technician later. Note: only
3-digit codes are generated by the battery. Codes of any other length
are generated by the forklift truck and you should consult with the
forklift dealer for more information and/or service.
To reset from a fault condition, disconnect the battery side of the truck
to battery communication cable. This will be a 12-pin black connector.
After waiting at least 30 seconds, reinsert the connector to power the
battery back on.
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