EnerSys EZSelect Plus Battery Selection System Owner’s Manual

: September 6, 2024
: EnerSys

Table of Contents

EZSelect Plus Battery Selection System
Specifications:
Product Information:
System Components:
Individual Components:
Spare Parts:
- Product Usage Instructions:
Installation Overview:
Tools Required:
Power Availability:
- FAQ:
Q: What should I do if the Control Box does not power on?
Q: How many Charger Monitoring Devices (CMD) can be connected

EZSelect Plus Battery Selection System

“`html

Specifications:

Manufacturer: EZSelectTM
Model: Plus Battery Selection System
Website: www.enersys.com
Control Box Voltage: 100-240 VAC
Control Box Amperage: 1.3A

Product Information:

The EZSelectTM Plus battery selection system is designed to
optimize battery room performance by simplifying the battery
selection process and providing essential management information on
batteries and chargers. The system consists of Charger Monitoring
Devices (CMD) mounted on each charger, a Control Box that tracks
charged batteries, and various display components for operator
guidance.

System Components:

Individual Components:

Control Box
Charger Monitoring Device (CMD)
Router
TV Driver
External Shouter
UPS Battery Backup

Spare Parts:

Data Cables
Splitter Kit for TV Monitor Display
Route Cables

Product Usage Instructions:

Installation Overview:

Control Box: Install the Control Box.
CMD Wiring Connections: Mount CMDs to
chargers, connect wiring from Control Box to first CMD, wire CMDs
together, and label chargers/battery bays.
Router & TV Driver: Connect the Router and
TV Driver.
Charger Configuration/Final Testing: Configure
Pools, Chargers, test upload capability, and provide operator
training.

Tools Required:

Drill and Bit
Screws & Anchors
Level
Screwdriver
Wire Cutters

Power Availability:

The Control Box requires a voltage of 100-240 VAC with an
amperage of 1.3A.

FAQ:

Q: What should I do if the Control Box does not power on?

A: Ensure that the power connection is secure and that the power
supply meets the specified requirements.

Q: How many Charger Monitoring Devices (CMD) can be connected

to a single Control Box?

A: The Control Box supports a maximum of 350 chargers and up to
9 pools.

“`

EZSELECTTM PLUS BATTERY SELECTION SYSTEM
OWNER’S MANUAL
www.enersys.com

CONTENTS
Introduction ………………………………………………………………… 3 System Components
Individual Components ……………………………………… 4 Spare Parts ……………………………………………………….. 5 Planning / Specifying Job Installation Overview ………………………………………… 7 Tools Required ………………………………………………….. 7 Power Availability ……………………………………………… 7 Control Box ………………………………………………………. 8 Charger Monitoring Devices (CMD) …………………. 8 Data Cable Requirements …………………………………… 8 Router Considerations ……………………………………….. 8 TV Driver Considerations …………………………………… 8 Installation & Commissioning Service ………………… 9 Pre-Installation Checklist ……………………………………. 9 Installation Installation Overview ………………………………………… 10 Control Box and CMD Installation …………………… 11 UPS & Router Installation ………………………………….. 12 TV Driver Installation …………………………………………. 13 External Shouter Installation (Optional) ……………… 14 Labelling the System …………………………………………. 14 System Configuration Touch Screen Display ………………………………………… 15 Passcode to Access Settings ………………………………. 15 Changing Passcodes …………………………………………. 15 Pools and Chargers Configuration ……………………… 16 Volume Adjustment …………………………………………… 17 Display Pools …………………………………………………….. 17 Running the System Dark …………………………………… 18 Final Inspection & Testing CMD …………………………………………………………………. 19 Quarantine ………………………………………………………… 19 CMD List …………………………………………………………… 20 ShouterTest ………………………………………………………. 20 Installation Checklist ………………………………………………….. 21 Operation Selecting the Next Available Battery …………………… 22 System Feedback ………………………………………………. 22 CMD Visual LED Indications ……………………………….. 22 Touch Screen Display ………………………………………… 23 System Daily Checks or Per Shift ………………………………. 26 Operation Checklist …………………………………………………….. 27 Troubleshooting ………………………………………………………….. 28 2

INTRODUCTION
The EZSelectTM Plus battery selection system helps to maximise the performance of your battery room. It not only streamlines the process of selecting the correct batteries during battery change, it provides valuable management information on the batteries and chargers.
A fully installed system will have a Charger Monitoring Device mounted on each charger. This monitoring device also referred to as a CMD. The primary function of the CMD is to detect when the charger finishes charging and send this information to the Control Box. The Control Box is wired to all CMD and uses information received from these CMD to keep track of all charged batteries. CMD/chargers are grouped into units called Pools.
Each Pool is dedicated to a specific type/size of battery in the facility. The Control Box’s other function is to inform the operator of which battery to pick to ensure maximum efficiency. This information is relayed through a display mounted on the control box, a Shouter that announces messages to the operator, and coloured LEDs mounted on the CMD.
For service, contact your sales representative: EnerSys® EMEA Headquarters Phone: +41 44 215 74 10 Address: EH Europe GmbH Baarerstrasse 18, 6300 Zug, Switzerland
Your Safety and the Safety of Others is Very Important
! WARNING You can be killed or seriously injured if you don’t follow instructions.
3

SYSTEM COMPONENTS
Individual Components
Figure 1: Overview of the EZSelectTM Plus battery selection system
TV Monitor *Source separately

iDisplay Touch Screen Built-in Shouter
4

Router

Control Box EZSelectTM Control Box

WIRELESS

PROG

ENET

REMOTE IDISPLAY

SIGN 1 SIGN 2 SIGN 3 BUS 1 BUS 2 BUS 3 BUS 4

USB

EXTERNAL SHOUTER

UPS Battery Backup
TV Driver
Power Connection
Mounting Feet

101

102

103

104

105

106

Charger Monitoring Device (CMD)

SYSTEM COMPONENTS
Spare Parts

EZS-143 8m Data Cable with one coupler

EZS-CB6700EU-16 EZSelectTM Plus battery selection system
Control Box (Max 350 chargers; Max 9 pools)

EZS-161
30m Data Cable with one coupler (Minimum 2 per Control Box, bus connection to first CMD)

EZS-SU600R Charger Monitor Device (CMD)
(2.1m data cable per CMD included)

EZS-511 UPS Battery Backup

EZS-ROU
Route (All cables included)

EZS-HDS6N2 TV Driver
(All cables and a mouse included)
5

SYSTEM COMPONENTS
Spare Parts (Optional)

EZS-SH6000 External Shouter
(15m speaker cable included)

EZS-231 Splitter Kit for TV Monitor Display

6

PLANNING/SPECIFYING JOB
Installation Overview
On-Site installation can be divided into three stages:
1. Control Box a. Control Box
2. CMD Wiring Connections a. Mount to Chargers b. Wiring from the Control Box to first CMD c. Wiring from CMD to CMD d. Labelling the Chargers/Battery Bays
3. Router & TV Driver a. Connecting Router b. Connecting TV Driver
4. Charger Configuration/Final Testing a. Configure Pools b. Configure Chargers c. Testing Upload Capability d. Operator Training
Tools Required

Drill and Bit

Appropriate Screws & Anchors for mounting

Level

Screwdriver

Wire Cutters

Power Availability
EZSelectTM Plus Battery Selection System Component Power Requirements:
Control Box Voltage: 100-240 VAC Amperage: 1.3A
Router Voltage: 100-240 VAC Amperage: 0.6A
Layout planning instructions to consider Extension cords can be used temporarily but surge protection is highly recommended for the Control Box.
7

PLANNING/SPECIFYING JOB

Control Box
· The Control Box should be located in a central position with sufficient room for the Router (EZS-ROU1) to also be installed nearby. Be sure that there is adequate clearance around the control box to connect cables, dimensions show in Figure 2.
· Mount in a visible area, free of obstructions.
Figure 2: Dimensions of Control Box

· Keep the component away from water sources such as emergency showers and sinks.
· The Control Box Will be powered via the EZS-ROU1 unit.
· Use appropriate anchors as necessary to support the Control Box (6.8 kg).

Charger Monitoring Devices (CMD)
One CMD is needed per charger. CMD universal and can be used for any voltage from 12V to 80V.
Router Considerations
The router housing (iHUB-ROU1) houses both the router and UPS for the Control Box so it is important it is both close to the Control Box and a 240V power source.
TV Driver Considerations
The TV Driver must be mounted within 3m of the Control Box. The TV should be mounted close to a suitable power and at a sufficiently high level in order to optimise visibility for the operators.

Data Cable Requirements
Data cables connect the Control Box to the CMD. When planning an installation, cable lengths should be kept to a minimum. With every Control Box you will have:
· 4 x 15m cables · 4 x cable couplers
The distance between the Control Box and the first CMD is critical. Two examples of bus cabling are shown in Figure 3.
Bus 1: 15m of cable needed even though it was only 3 meters from the Control Box to the first CMD.
Bus 2: 30m of cable needed as it was located on the other side of the aisle to the first CMD.

8

PLANNING/SPECIFYING JOB

Installation & Commissioning Services
The EZSelectTM Plus battery selection system is designed to not require commissioning by EnerSys®, but if assistance is required, it is offered by request. Installation videos are available online.

Pre-Installation Checklist

Task
A. Plan Location of Control Box and Router
· Power for Control Box and Router · Near chargers · Plan for data cable run to the first CMD in each bus
B. Gather all required tools and equipment
· Ladders and/or scissor lifts · Power tools – for mounting Control Box, etc. · Hand tools – wire cutters, screwdriver · Extension cords for temporary power · Anchors for mounting components as necessary

Status

9

INSTALLATION
System Overview
Figure 3: Sample layout of the EZSelectTM Plus battery selection system installation
*TV Monitor sources separately
PALLET 102

WIRELESS

PROG

ENET

REMOTE IDISPLAY

SIGN 1 SIGN 2 SIGN 3 BUS 1 BUS 2 BUS 3 BUS 4

USB

EXTERNAL SHOUTER

CMD Bus 1: Run 50ft (15m)
10

101

102

103

104

105

106

Pallet Pool

CMD
*For LED indications, refers to Figure 4.

INSTALLATION

Control Box & CMD Installation

1

2

180O

Install Straight Mount Mount the straight to the wall at eye height
using four screws/anchors and a level.
3

Install Control Box Slide the Control Box into the bracket.
4

WIRELESS

PROG

ENET

REMOTE IDISPLAY

SIGN 1 SIGN 2 SIGN 3 BUS 1 BUS 2 BUS 3 BUS 4

USB

WIRELESS

PROG

ENET

REMOTE IDISPLAY

SIGN 1 SIGN 2 SIGN 3 BUS 1 BUS 2 BUS 3 BUS 4

USB

EXTERNAL SHOUTER

Install Control Box Mount the control box to the wall at eye height
using four screws/anchors and a level.
5

Insert the first CMD data cable through bottom port into one of the available bus sockets in the Control Box.
6

Insert the first CMD data cable into a socket on the first CMD. Connect the next data cable into the other socket.
7
–

Mount the CMD with cable ties so that it is visible, safe and secure. Connect CMD in series until all CMD on bus are connected.
8
–

Connect the two FlexiTaps to the sides of the connector. Place the connector between the positive and negative cables. *Ensure they are firmly attached to the connector and cables, the pins
are in the centre of the cables and do not bend the pins.

Secure the connector with cable ties. Confirm amber LED illuminates on the CMD with a battery connected.
11

INSTALLATION

UPS & Router Installation

1
180O
Mount the Router Box near the Control Box and suitable power supply using four screws, suitable wall anchors
and a level.
3

2

2 1

PROG

ENET

REMOTE IDISPLAY

SIGN 1 SIGN 2 SIGN 3 BUS 1 BUS 2 BUS 3 BUS 4

USB

3
EXTERNAL SHOUTER

4

2
1 3

WIRELESS

PROG

ENET

REMOTE IDISPLAY

SIGN 1 SIGN 2 SIGN 3 BUS 1 BUS 2 BUS 3 BUS 4

USB

EXTERNAL SHOUTER

4

Place the UPS battery backup in the enclosure box, connect it into power source and plug Control Box power cord into UPS.

4

PALLET 102 REACH 203

StSattautsus

History

To Do (0)

Maintenance

Settings

MOBILE

SIM SIM1

WIFI

RESET

SIM SIM2
WIFI

MOBILE

Turn on the UPS.
5

Connect the two WiFi antennae to the Router WiFi connectors.
6

MOBILE

SIM SIM1

WIFI

RESET

SIM SIM2
WIFI

MOBILE

LAN1

LAN2

LAN3

WAN

PWR

WIRELESS

PROG

ENET

REMOTE IDISPLAY

SIGN 1 SIGN 2 SIGN 3 BUS 1 BUS 2 BUS 3 BUS 4

USB

EXTERNAL SHOUTER

WIRELESS

PROG

ENET

REMOTE IDISPLAY

SIGN 1 SIGN 2 SIGN 3 BUS 1 BUS 2 BUS 3 BUS 4

USB

EXTERNAL SHOUTER

Connect the two wired antennae to the Router mobile connectors. Place one on top of the enclosure box, and the
other one as high as possible. *Keep at least 1m distance between the two wired antennae.
7

LAN1

LAN2

LAN3

WAN

PWR

Connect the Router to power source. 12

Connect the data cable from one of the available sign sockets in the Control Box to the LAN Ethernet port on the Router.
After you have installed the Router Box, UPS and powered up all components, wait for five to ten minutes so it has established a connection and then reboot the Control Box.
To do this, go to “Settings,” “Internet,” and “Reboot.” You are now ready to do a data upload test. On the same Internet Settings Screen, select the “Upload Now” button and exit.
After five minutes press the Status tab on the home screen and in the bottom left hand corner you will see “Time Since Last Upload.” This should be within the last 5 minutes.

INSTALLATION

TV Driver Installation
1
180O
180O
Mount the TV Driver to the wall using four screws/anchors and a level. Keep the distance between the Control Box and the TV Driver under 2.5m to make sure there’s a good connection.
3
TV Monitor sources
separately.

2

WIRELESS

PROG

ENET

REMOTE IDISPLAY

SIGN 1 SIGN 2 SIGN 3 BUS 1 BUS 2 BUS 3 BUS 4

USB

EXTERNAL SHOUTER

Connect the TV Driver to the `Remote iDisplay’ socket in the Control Box.
4

Connect the HDMI cable to the TV Driver and the TV Monitor*.
Start-up Sequence

PALLET 102 REACH 203

PALLET
102
REACH
203

StSattautsus

History

To Do (0)

Maintenance

Settings

Connect the TV Driver to power source.
5
MINS

ON

Switch on The TV, after 5 minutes with the Control Box powered on, power up the TV Driver.

13

INSTALLATION

External Shouter Installation (Optional)

1

2

SIGN 3 BUS 1 BUS 2 BUS 3 BUS 4

USB

PALLET
102
REACH
203

StSattautsus

History

To Do (0)

Maintenance

Settings

EXTERNAL SHOUTER

WIRELESS

PROG

ENET

REMOTE IDISPLAY

SIGN 1 SIGN 2 SIGN 3 BUS 1 BUS 2 BUS 3 BUS 4

USB

EXTERNAL SHOUTER

Mount the external shouter above the Control Box within 15m of the provided audio cable.

Connect the two leads into the external shouter sockets in the Control Box.

Labelling The System
The EZSelectTM Plus battery selection system communicates with the operator by referencing a charger number. It is always important to keep the charger numbering system organized to maintain the smooth process of selecting a battery.
When setting up the charger numbering system in the facility it is recommended to follow a 3 digit format (as shown in all examples within this manual) where the first digit references the pool and the second and third digit reference the battery number in that pool.

A pool is a group of batteries that have been grouped by type, i.e. Powered Pallet Trucks and Reach Trucks. As a basic rule of organising batteries, there will always be at least one pool per type of battery in the facility. There are some scenarios where it would be preferable to have more than one pool per type of battery. The EZSelectTM Plus battery selection system has a maximum availability of 9 pools.
Both the TV screen and the screen on the Control Box should match the charger labels making it easier for operators to navigate to the correct battery. An example is shown below.

PALLET
101 102 103

REACH
201 202 203

Example of 3-digit organization

*Charger labels will be provided with each EZSelectTM Plus battery selection system.

14

SYSTEM CONFIGURATION

Touch Screen Display

Signal showing communication between
display and controller.
Next battery to take for each of the pools.
*The home screen will automatically display up to 9 pools.

PALLET
102
REACH
203

StSattautsus

History

To Do (0)

Maintenance

Settings

Click on the “To Do” button if it turns red – Check if chargers in quarantine or CMD not reporting.

Passcode to Access Settings

1
PALLET
102
REACH
203

StSattautsus

History

To Do (0)

Maintenance

Click Settings on Home Screen.

Settings

2 Enter Settings Passcode

7

8

9

4

5

6

1

2

3

0 <<< OK

Enter default passcode 919191 then click OK.

Changing Passcodes

1

Settings

2

Language

EN

Set Settings Passcode

Set a new Settings Passcode

Date & Time Pools & Chargers
Internet

2013-08-07 09:42
0 Pools 0 Chargers
Automatic (DHCP)

Set Maint Mode Passcode

0 Total Sentinels Assigned 0 of which are Non-Reporting

Sentinel List

System Information

1/2

Click Settings Passcode or Maint Mode Passcode.

7

8

9

4

5

6

1

2

3

0 <<< OK

Enter the New Passcode# then click OK.

*If you prefer to remove the passcode(s) during installation, leave it blank and click OK. Setting the passcode before leaving site is recommended.

The password(s) can be recovered from EnerSys® if lost by contacting the

correct regional department with the system Control Box serial number.
15

SYSTEM CONFIGURATION

Pools and Chargers Configuration

1

Language

EN

Settings

Set Settings Passcode

Date & Time Pools & Chargers
Internet

2013-08-07 09:42
0 Pools 0 Chargers
Automatic (DHCP)

Set Maint Mode Passcode

0 Total Sentinels Assigned 0 of which are Non-Reporting

Sentinel List

System Information

2
Pool #
1 2 3 4 5

Set Up Pools & Chargers

Pool Name

Voltage
Set V

Set V

Charger Count
Add Charger (0) Add Charger (0) Add Charger (0) Add Charger (0) Add Charger (0)

1/2
Click Pools & Chargers under the settings menu.

3
Pool #
1 2 3 4 5

Set Up Pools & Chargers

Pool Name
PALLET

Voltage
Set V

Set V

Charger Count
Add Charger (0) Add Charger (0) Add Charger (0) Add Charger (0) Add Charger (0)

Click on the first blank Pool key and type in the name of the pool.

4

Set Battery Voltage to PALLET

24

Notice the Pool name is now set up. Click on the Set V button that corresponds
to the pool’s voltage.

5
Pool #
1 2 3 4 5

Set Up Pools & Chargers

Pool Name
PALLET

Voltage
24

Set V

Charger Count
Add Charger (0) Add Charger (0) Add Charger (0) Add Charger (0) Add Charger (0)

Select the correct pool voltage.

6
List of Chargers

Add Chargers to PALLET
To add a charger to this pool, plug a battery into the charger. If there is already a battery, unplug it and then plug it in.

Add Charger(s) to the pool.

7

Set Charger ID

101

7

8

9

4

5

6

1

2

3

ABC 0 <<< OK
Enter the number to set Charger ID. *This screen will pop up when EZSelectTM Plus battery selection
system detects the connected battery.
16

Go to the charger. Disconnect and reconnect the charger you want to add.
Repeat step 1 to 6 to set up additional pools and chargers. N.B. This is the number that will be displayed on the TV. It must also match the charger labels.

SYSTEM CONFIGURATION

Volume Adjustment

1

Settings

Display Pools

1 through 9

Volume

Good Pick Volume = 3 Mispick Volume = 3

Communication Test

Quarantine

Sentinel Outputs

Long
Pair 1 = 0 + 0 Pair 2 = 0 + 0 Pair 3 = 0 + 0 Pair 4 = 0 + 0

Message Length Link Pools

2/2
Click Volume under the settings menu.

2
Good Pick

Set Volume
Mispick

3 Test

Set the volume between 0 (silent) and 5 (maximum). The test button will sound the alarm once.

Display Pools

1

Settings

Display Pools

1 through 9

Volume

Good Pick Volume = 3 Mispick Volume = 3

Communication Test

Quarantine

Sentinel Outputs

Long
Pair 1 = 0 + 0 Pair 2 = 0 + 0 Pair 3 = 0 + 0 Pair 4 = 0 + 0

Message Length Link Pools

2/2
Click Display Pools under the settings menu.

2

Display Pools

1 through 9 1 through 5 6 through 9

The iDisplay is set to display all by default, however you can select only particular pools to show.

17

SYSTEM CONFIGURATION

Running The System In Study Mode

To quantify the benefits of the EZSelectTM battery selection system, it is suggested that you begin with a benchmark period of two weeks where the system gathers an initial baseline usage data sample. It’s recommend on every new install in order to show a clear before and after. Running the1system in Study Mode means that the system

is gathering information but there is no battery selection guidance provided. This way you can tell what is really happening in your battery room, so you can compare the raw data with the improved performance once the system is giving commands.
2

1

Settings

23

Display Pools

1 through 9

Sentinel Outputs

Volume

Good Pick Volume = 3 Mispick Volume = 3

Communication Test

Quarantine

Long
Pair 1 = 0 + 0 Pair 2 = 0 + 0 Pair 3 = 0 + 0 Pair 4 = 0 + 0

Message Length Link Pools

Sentinel Outputs
Blue Light
OFF
Output Relay
OFF

2/2
Click Sentinel Outputs under the settings menu. (N.B. A CMD is referred to as a Sentinel in the panel software.)
3

Set both the Blue Light and Output Relay to OFF.

Turn off the iDisplay by pressing the power button on the front of the Control Box. This will also turn off the sound.
N.B. To turn the system to function normally, reverse previous steps.

18

FINAL INSPECTION & TESTING

CHARGER MONITORING DEVICE (CMD)

If you have successfully run the installation wizard for all of the CMD, then the green LED will be solid on each one.

see the charger ID. If you don’t see the pool and charger ID you expected, then the system may be
misconfigured.

If you want to double check the connection, you can disconnect a battery from a charger and then watch the system status screen. You should

The charger ID will move from column to column as the status changes.

QUARANTINE
The Quarantine column shows the quantity of chargers that have not started or have not completed the charge of a battery that has been connected to it for 24 hours. The system quarantines the battery by taking it out of the queue, and if the issue is not resolved within 72 hours, the battery is returned to the queue.
3 days is the default factory setting.
What to do if a charger is shown under quarantine: · If any charger ID are listed in the column marked
“Quarantine”, check to see if the charger indicates a fault.

· Confirm that the amber LED is illuminated on the
CMD, and that a battery is connected. · If the display and all indicator lights on the
charger are blank, check to see if there is power
to the charger. · If the charger is functioning properly, check the
voltage of the battery as some chargers will not
recognize an over discharged battery.
· To remove the battery from Quarantine,
disconnect and reconnect the battery.

1

Settings

Display Pools

1 through 9

Volume

Good Pick Volume = 3 Mispick Volume = 3

Communication Test

Quarantine

Sentinel Outputs

Long
Pair 1 = 0 + 0 Pair 2 = 0 + 0 Pair 3 = 0 + 0 Pair 4 = 0 + 0

Message Length Link Pools

2/2
Click Quarantine.

2

Set Number of Days in Quarantine

3

Increase or decrease the numbers of days passed before a charger is placed into Quarantine.

19

FINAL INSPECTION & TESTING

CMD LIST

1

Language

EN

Settings

Set Settings Passcode

Date & Time Pools & Chargers
Internet

2013-08-07 09:42
0 Pools 0 Chargers
Automatic (DHCP)

Set Maint Mode Passcode

0 Total Sentinels Assigned 0 of which are Non-Reporting

Sentinel List

System Information

1/2

Click Sentinel List. (N.B. A CMD is referred to as a Sentinel in the panel software.)

3

SentinLeol Erdeimt ipsum

Sentinel Serial Number Software Version Status Bus Voltage Bus Number

: 10087 : 12 : Terminated Normally : 22.93 : 1

Pool ID
3
Charger ID

Delete Sentinel

Blue ON

101

Unassign Sentinel

Blue OFF

Refresh

Press Blue ON to find the correct CMD and check details.
A CMD can be moved to a different Pool by scrolling through Pool ID. The charger number can be changed by pressing Charger ID.
Press Blue OFF when corrections have been made.

2

Unassigned SentiLneolsre- mSenitpinseul Lmist

Pool #

Chg ID

Serial #

Ver

Pool #

0

10003

12

Unknown

0

10155

12

Unknown

0

10086

12

Unknown

0

10185

12

Unknown

0

10191

12

Unknown

Reporting
Yes Yes Yes Yes Yes

Refresh

This shows the number of unassigned CMD. Press the arrow on the right hand side to edit the CMD details.

This function can also be used to program the CMD. If you know the CMD serial number you can assign it to a pool and give it a charger ID. You can then verify it is correct and all communication is working by turning on and off the blue light.

Shouter Test

1
Good Pick

Set Volume
Mispick

3 Test

Test the shouter functionality by either unplugging a battery or pressing the Test button on the Set Volume screen.

20

INSTALLATION CHECKLIST

Task
1. Make sure all CMDs are displaying a solid green light.
2. Make sure all CMDs are assigned and reporting via the CMD List under Settings on the home screen.
3. Test the Shouter for “Correct” and “Incorrect” battery pick sounds from the menu. Test this by clicking “Settings” then “Volume.” Also select desired volume at this time.
4. Test the upload capabilities of the EZSelectTM Plus battery selection system via the Internet.
5. If the passwords were disabled during installation, reset the Maintenance default password to “11111” and the Settings default password to “919191”. Or set passwords of your own choosing.
6. Check that the date and time are set correctly.
7. Check that all chargers are labelled correctly using the included labels.
8. Check Charger Settings to make sure “Cool Down” setting and “Delay Equalization Charge” are set to “Off.”

Status

21

OPERATION

Selecting The Next Available Battery

Keep all batteries plugged in until they are selected unless they are selected for maintenance. The system detects when a battery is connected to the

charger, when the charger starts and finishes, and
how long the battery is connected to the charger before it is picked.

How to select next available battery:

1 TV Display
Indicates the pool(s) and the next battery to select.

2 Touch Screen Display
Indicates the next battery to select.

3 CMD
Blue LED indicates the battery is
available to pick.

System Feedback
· The shouter on the Control Box sounds with a pleasant chime when the battery indicated by the system is selected.
· The shouter on the Control Box sounds with an alarm and message when a battery other than the one indicated by the system is selected. When this occurs, the system considers it as a `mispick’.

· All mispicks are logged by the system and can
be viewed through the History tab on the Home Screen of the touch screen display or through
the website, batterymanagement.net.

Charging Monitoring Device (CMD) Visual LED Indications

Figure 4: LED Indications for CMD

(Solid) Good Connection (Flashing) Unstable Connection

Battery Charging

22

Next Battery to Pick

Communication Fault
*If the red fault light is on, please replace the data cable.

OPERATION

Touch Screen Display

Signal showing communication between
display and controller.
Next battery to take for each of the pools.
*The home screen will automatically display up to 9 pools.

PALLET
102
REACH
203

StSattautsus

History

To Do (0)

Maintenance

Settings

Click on the “To Do” button if it turns red – Check if chargers in quarantine or CMD not reporting.

A. Status
1
PALLET
102
REACH
203

StSattautsus

History

To Do (0)

Maintenance

Click Status on Home Screen.

Settings

If no battery number shown on the home screen, check the `Batteries Available’ under Status.

3

PALLET Queue

Available
102 109 110 108

Charging
103 107 106 105

Connected Not Charging
104

No Battery Connected
101

Quarantine

Unknown

2
Pool Name
PALLET REACH

Next Battery on Charger
104
205

Status

Batteries Available
4

Charging

Connect Not Charging

No Battery Connected

Quarantine

Unknown

4

1

0

2

3

0

Time Since Last Upload 09:31:00

Serial Number 4503e6af

2024-04-08 15:26

Click the pool name (e.g. PALLET) to check the batteries status in the pool.

The queue screen shows the status of each of the chargers in the pool.

23

OPERATION

B. History
1
PALLET
102
REACH
203

StSattautsus

History

To Do (0)

Maintenance

Settings

Click History on Home Screen. The statistics for the last seven days will be displayed.

3

PALLET – Mispicks

Date
07/04/2024 08/04/2024

Time
09:07:05 14:36:44

Charger
104 107

Type
Mispick Mispick

The last seven days history of the chargers detail under the selected metrics will be shown.

2
Pool Name
PALLET REACH

7 Day Statistics

Selections
44 43 4 4 4

Mispicks
2 2

Zero Available Picks
0
0

Minimum Batteries Available
Graph
Graph

Select the Green Button for more detailed batteries information of respective pool.
*Definition of the metrics Selections: The number of battery was pick for that pool.
Mispicks: The number of times a battery was picked from the pool instead of the one chosen by the system.
Zero Available Picks: The number of times a battery was picked when no batteries were fully charged.
Minimum Batteries Available: A graph displays the daily count of fully charged batteries over the last seven days.

C. To Do
1
PALLET
102
REACH
203

StSattautsus

History

To Do (1)

Maintenance

Settings

Click To Do on Home Screen if it turns red. Check if chargers in quarantine, any CMD not reporting
or chargers to be switched.

*The number in the bracket ( ) shows how many fault alerts.

2

To Do List

Action
Chargers in quarantine PALLET REACH

Charger
101 44 43 44 43
3

Time ago
00:021 2

If there are any alerts, they will be listed.

24

OPERATION

D. Maintenance
1
PALLET
—
REACH
—

StSattautsus

History

To Do (0) Maintenance

Click Maintenance on Home Screen to pick batteries that need service.

Settings

*While Maintenance Mode is on, the system does not show which battery to pick next. But all picks are still recorded.

3

Maintenance Mode

Set Maintenance Mode
ON

Events During Maintenance Mode

Date

Time

Charger

Type

Maintenance Mode Duration (Minutes)
30

2

Enter Settings Passcode

7

8

9

4

5

6

1

2

3

0 <<< OK
Enter the default Passcode 11111 then click OK.

*If you prefer to remove the passcode during operation, refer to Changing Passcodes section.

The duration of Maintenance Mode can be set from 5 – 120 minutes. An auto timer then returns the system
to normal operating mode.
Maintenance Mode can also be cancelled manually.

E. Settings
1
PALLET
102
REACH
203

StSattautsus

History

To Do (0)

Maintenance

Click Settings on Home Screen.

Settings

*Refer to System Configuration section for more detail information.

2

Enter Settings Passcode

7

8

9

4

5

6

1

2

3

0 <<< OK
Enter default passcode 919191 then click OK.

*To change the passcode, refer to Changing Passcodes section.

25

SYSTEM DAILY CHECKS/PER SHIFT

PALLET
102
REACH
203

StSattautsus

History

To Do (0)

Maintenance

Settings

Step 1
Check the system Status in the beginning of the day or beginning of the shift.

Pool Name
PALLET REACH

Next Battery on Charger
–
–

Status

Batteries Available
0

Connect Charging Not Charging

No Battery Connected

Quarantine

Unknown

4

1

0

2

3

0

Time Since Last Upload 09:31:00

Serial Number 4503e6af

2024-04-08 15:26

Step 2
Determine if the following conditions exist:
1. No batteries available 2. Batteries connected but not charging 3. Chargers with no battery connected 4. Batteries in quarantine 5. Unknown
*If any of these conditions exist, refer to Troubleshooting section.

Pool Name
PALLET REACH

Next Battery on Charger
–
–

Status

Batteries Available
0

Connect Charging Not Charging

No Battery Connected

Quarantine

Unknown

4

1

0

2

3

0

Time Since Last Upload 99:59:59

Serial Number 4503e6af

2024-04-08 15:26

Step 3
If `Time Since Last Upload’ reads 99:59:59, it means the system is not uploading. Please contact your service distributor.

PALLET
102
REACH
203

StSattautsus

History

To Do (1)

Maintenance

Settings

Step 4
Check the To Do button in the beginning of the day or in the beginning of the shift, click to see if any fault alert is on if it turns red.

26

OPERATION CHECKLIST

Task 1. Are there batteries available?

Yes No

Status
Quantity Available (If yes) Pool 1: Pool 2: Pool 3: Pool 4: Pool 5: Pool 6: Pool 7: Pool 8: Pool 9: __

2. Are there any pools with no batteries available? 3. Are there batteries connected but not charging? 4. Are there chargers with no battery connected? 5. Are there chargers in Quarantine? 6. Are there chargers with Unknown Status?

Yes No

List Pools (If yes)

Yes No

List Chargers (If yes)

Action Taken

Yes No

List Chargers (If yes)

Action Taken

Yes No

List Chargers (If yes)

Action Taken

Yes No

List Chargers (If yes)

Action Taken

7. Time since last upload

27

TROUBLESHOOTING

The Display Shows Dashes

1
PALLET
—
REACH
203

2
Pool Name
PALLET REACH

Next Battery on Charger
104
205

Status

Batteries Available
0

Charging

Connect Not Charging

No Battery Connected

Quarantine

Unknown

4

1

0

2

3

0

StSattautsus

History

To Do (0)

Maintenance

Settings

If the home screen shows dashes instead of a charger number, check the Status screen.

Time Since Last Upload 09:31:00

Serial Number 4503e6af

2024-04-08 15:26

Check if there are any batteries available.

Troubleshooting from Status Screen

1
PALLET
102
REACH
203

2
Pool Name
PALLET REACH

Next Battery on Charger
104
205

Status

Batteries Available
0

Connect Charging Not Charging

No Battery Connected

Quarantine

Unknown

4

1

0

2

3

0

StSattautsus

History

To Do (0)

Maintenance

Click Status on Home Screen.

Settings

Time Since Last Upload 09:31:00

Serial Number 4503e6af

2024-04-08 15:26

When you are in troubleshooting, focus on the last four columns: Connect Not Charging, No Battery Connected,
Quarantine and Unknown.

A. Connected Not Charging

A battery has just been connected and that the charger has not turned on yet. OR an issue with the battery or charger such that the charger will not start its charging cycle.

Pool Name
PALLET REACH

Next Battery on Charger
104
205

Status

Batteries Available
0

Charging

Connect Not Charging

No Battery Connected

Quarantine

Unknown

4

1

0

2

3

0

Check if: Any charger indicates a fault.
The amber LED is flashing on the CMD, and a battery is connected.
The charger is connected to power source if the display and all indicator lights on the charger are blank.

The charger is set for a delayed start.

Time Since Last Upload 09:31:00

Serial Number 4503e6af

2024-04-08 15:26

The battery voltage is able to function with the charger if the charger is functioning properly, as some chargers will not recognize an over discharged battery.

28

TROUBLESHOOTING

B. No Battery Connected

The system does not indicate that a battery has been connected.

Pool Name
PALLET REACH

Next Battery on Charger
104
205

Status

Batteries Available
0

Connect Charging Not Charging

No Battery Connected

Quarantine

Unknown

4

1

0

2

3

0

Check if: A battery is in the charging slot on the battery rack.
There is a battery connected to the charger listed.
The amber LED on the CMD is on if a battery is connected.

Time Since Last Upload 09:31:00

Serial Number 4503e6af

2024-04-08 15:26

The amber LED on the CMD is not on even if a battery is connected. Check the battery connector to make sure it is not broken.
The amber LED on the CMD is not on even if a battery is connected. Check the pin of the FlexiTap on the CMD is in the centre of the cable and do not bend the pin.

C. Quarantine

This shows the quantity of chargers where a battery has been connected, but the charger has not started within 24 hours. The system quarantines the battery by taking it out of the queue, and if the issue is not resolved within 72 hours, the battery is returned to the queue.

Pool Name
PALLET REACH

Next Battery on Charger
104
205

Status

Batteries Available
0

Charging

Connect Not Charging

No Battery Connected

Quarantine

Unknown

4

1

0

2

3

0

Check if: Any charger indicates a fault.
The amber LED is flashing on the CMD, and a battery is connected.
The charger is connected to power source if the display and all indicator lights on the charger are blank.

Time Since Last Upload 09:31:00

Serial Number 4503e6af

2024-04-08 15:26

The battery voltage is able to function with the charger if the charger is functioning properly, as some chargers will not recognize an over discharged battery.
To take a battery out of quarantine, disconnect the battery from the charger and reconnect the battery.

D. Unknown

This shows the number of chargers with an unknown status according to the system.

Pool Name
PALLET REACH

Next Battery on Charger
104
205

Status

Batteries Available
0

Charging

Connect Not Charging

No Battery Connected

Quarantine

Unknown

4

1

0

2

3

0

Check if: The green LED on the CMD is solid. If it does, wait for a few minutes and check the Status screen again.
The green LED on the CMD is not on. Check the data cables to make sure they are secure and not broken/ pinched.

The green LED on the CMD is not on. Check the data cable is plugged into the Control Box.

Time Since Last Upload 09:31:00

Serial Number 4503e6af

2024-04-08 15:26

The green LED on the CMD is not on. Check the data cable is connected to the first CMD and the cable is connected between each CMD.

The green LED on the CMD is not on. Check the Control Box is connected to a power source.

The green LED on the CMD is flashing. Check the CMD has been assigned to a pool through the charger configuration.
29

NOTES
30

www.enersys.com © 2024 EnerSys. All Rights Reserved. All trademarks and logos are the property of EnerSys expect Unistrut, CE, and UKCA which is not the property of EnerSys. Subject to revision without prior notice. E&O.E. R4-25072024 EMEA-EN-OM-EZSELECT-PLUS-0724