lithium-ion 4kwh battery system ess pv48v 774423 56 v / …...ess pv48v lithium-ion 4kwh battery...

INDUSTRIAL BATTERY GROUP Doc Ref:

SDU/EEA/IL/13-0649 User’s Manual

ESS PV48V Lithium-Ion 4kWh Battery System (56 V / 82 Ah)

This document is Saft property. Any reproduction, diffusion or communication, even partial, are liable to prosecution without formal authorization.

Lithium-Ion 4kWh Battery System

ESS PV48V 774423

56 V / 82 Ah


SDU/EEA/IL/13-0649

User’s Manual ESS PV48V Lithium-Ion 4kWh Battery System (56 V / 82

Ah)

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DOCUMENT REVISION

Version Date Changes

1 05/03/2013 Initial version

It is mandatory to read the user and the maintenance manuals prior to any use, installation or maintenance of a Saft battery. All instructions must be carefully complied with. In case

any of the instructions contained in the user and the maintenance manuals are not applied, Saft’s warranty on the battery is no longer applicable and Saft disclaim any liability for any

and all direct, indirect or consequential damages or losses resulting thereof.

To highlight important points, the following symbols will be used:

: Indicates a possibility of injury or serious equipment damage if instructions are not followed

: Indicates helpful information


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SAFETY RULES

WARNING

A battery can store energy in electrochemical form. It is an active device that contains a large quantity of energy. As with any electrical device or energy storage (such as a tank of fuel), safety instructions must be understood and applied by all persons in potential contact with this device. Failing to install the battery in an enclosed room and to reserve an access to specialists, it is particularly important to ensure compliance with these requirements in a residential environment, all people, and for the duration operation of the battery in this environment. The owner of the room must ensure that no unauthorized person, especially children, intervenes on the battery. As with any electrical device, the non-observance of safety exposes people to hazards.

Safety rules for the user

Access

The battery must be installed inside its 19’’ racks / cabinet.

The access to the battery should be prohibited to unauthorized persons, including children. The access to battery organs inside the cabinet is restricted to authorized personnel familiar with the risks associated with batteries and electrical power.

The cabinet is delivered with a specific tool to open the cabinet door. This tool must be kept by the installer.

For the installers, always use insulated tools and personal protection (60V) for handling operations with presence of energized parts.

Installation

The system must be installed in non-permanent living area.

The installation must be compliant with the local regulations for the prevention of fire and smoke,

electrical safety, construction, earthquake, flood,…

The room must have openings to outdoor (windows or/and doors) allowing an important and fast air

exchange in the case of accident. This opening must allow an air exchange of 125m³/h. In the case

where it’s impossible to respect this rule, contact SAFT to find an alternative airflow solution.

It’s recommended to install the battery inside a room of 8m³ at least.

It’s mandatory to install smoke sensors or/and CO above the installation of battery.

All materials and protective coatings close to the system shall not be flammable in order to avoid fire

propagation.

It’s forbidden to store or put flammable products or dangerous products near to the battery or on the

cabinet (oil, coating, alcohol…).

250 mm is the minimal distance between the cabinet and the wall and roof of the room.

In the case where there are 2 C4-ion cabinets would be installed in the same room, it is

recommended to respect 100 mm if side by side, and 200 mm if back to back.

It’s recommended to avoid a liquid above the cabinet, and also avoid all fluid projection on the

battery.


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The battery must not be located near to fire of hot source (> 70°C). The non-respect of this rule can

provoke an overheating or battery fire.

The using of the battery in a hot environment decreases the lifetime and the performances.

In case of malfunction or accident, when detector alarm fire

Disconnect the battery immediately if a fault occurs during operation, such as the unfamiliar odors,

heat emission, distortion, etc… Contact Saft. To disconnect the battery it is necessary to put the

switch disconnect in the "off" position and put the switch of BMM on the "off" position.

In case of battery failure with smoke emission, ventilate fastly the room thanks to openings.

Evacuate the room (included the animals) and wait 20min at least before to enter again (for volume

of 6m³ to 24m³). If no ventilation, wait 2h for a room of 16m³ and 3h for 24m³. Contact SAFT for

more information if a room with different volume.

Safety rules for the battery use

The compliant of the battery is ensured by the development and the respect of safety rules by the user. Violation of these rules may result in overheating or fire of the battery and cause severe injury.

Do not short-circuit the battery.

Do not inverse the polarity of the battery.

Do not overcharge or overdischarge

Respect the voltage levels indicated in the user manuals

Do not open the cabinet, the BMM or modules

Do not work the battery without the BMM

Do not expose the battery to an excessive mechanical stress

Do not expose the battery to water and condensation

Install the battery in a area compliant to the pollution level 2 according to EN 60664-1


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TABLE OF CONTENTS

1. INTRODUCTION ....................................................................................................................... 7

Applicable documents ......................................................................................................... 7 1.1. Reference documents ......................................................................................................... 7 1.2. Acronyms ............................................................................................................................ 7 1.3.

2. UNPACKING AND INSPECTION ............................................................................................. 8 Battery characteristics ....................................................................................................... 10 2.1.

3. GENERAL DESCRIPTION ..................................................................................................... 12 Battery System ................................................................................................................. 12 3.1. BMM Earthing ................................................................................................................... 15 3.2. Insulation groups .............................................................................................................. 15 3.3. Precharge management ................................................................................................... 16 3.4.

4. MECHANICAL INSTALLATION ............................................................................................. 17 Safety rules ....................................................................................................................... 17 4.1. General requirements for the cabinet................................................................................ 17 4.2. Mechanical installation inside the electrical cabinet .......................................................... 17 4.3.

5. ELECTRICAL INSTALLATION .............................................................................................. 19 Recommendations prior to connection.............................................................................. 19 5.1. Electrical connections ....................................................................................................... 19 5.2. Electronic and software interfaces .................................................................................... 21 5.3.

6. OPERATION DESCRIPTION .................................................................................................. 25 General principle ............................................................................................................... 25 6.1. Safety functions inside the BMM ....................................................................................... 25 6.2. CAN bus ........................................................................................................................... 26 6.3. Battery system start-up and shutdown: ............................................................................. 26 6.4. Battery system States/Modes: .......................................................................................... 27 6.5. Battery charging ................................................................................................................ 30 6.6. Battery discharge (operation) ............................................................................................ 32 6.7. Alarms and warnings ........................................................................................................ 33 6.8. Balancing .......................................................................................................................... 34 6.9.

Data exchange from BMM to application controller ....................................................... 34 6.10. Data exchange from application controller to BMM ....................................................... 35 6.11.

7. HANDLING & STORAGE ....................................................................................................... 36 Handling ............................................................................................................................ 36 7.1. Storage ............................................................................................................................. 36 7.2.

8. MAINTENANCE ...................................................................................................................... 37 9. PACKAGING AND TRANSPORT .......................................................................................... 38

Battery classification ......................................................................................................... 38 9.1. Training ............................................................................................................................. 38 9.2. Battery packing ................................................................................................................. 38 9.3. Charging state for transportation ...................................................................................... 38 9.4. Documentation for transport ............................................................................................. 38 9.5.

10. DISPOSAL ........................................................................................................................... 39 APPENDIX I: MECHANICAL INTERFACES ................................................................................. 40 APPENDIX II: Fault codes and alarm list of the battery system ............................................... 41 APPENDIX III: CHARGE THE MODULE IN STORAGE ............................................................... 47


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LIST OF TABLES Table 1 : Battery System Characteristic ........................................................................................................................................... 10 Table 2 : BMM insulation groups description .................................................................................................................................. 15 Table 3: Normal Charge for the battery system ................................................................................................................................ 31 Table 4: Normal Discharge for the battery system ........................................................................................................................... 33 Table 5 : Storage duration ................................................................................................................................................................ 36

LIST OF FIGURES Figure 1: Battery System .................................................................................................................................................................... 8 Figure 2 : Synerion 24M Module ........................................................................................................................................................ 9 Figure 3 : BMM ESS PV48V............................................................................................................................................................... 9 Figure 4: Battery Architecture .......................................................................................................................................................... 11 Figure 5 : ESSU overview ................................................................................................................................................................. 12 Figure 6 : Module overview .............................................................................................................................................................. 13 Figure 7 : BMM overview ................................................................................................................................................................. 14 Figure 8 : Protective Earth symbol ................................................................................................................................................... 15 Figure 9 : BMM insulation group ..................................................................................................................................................... 16 Figure 10 : Mechanical installation ................................................................................................................................................. 18 Figure 11 : Detail of external BMM connection ............................................................................................................................... 20 Figure 12 : Communication wires .................................................................................................................................................... 20 Figure 13 : Power cables .................................................................................................................................................................. 21 Figure 14 : Switch “Start” Position ................................................................................................................................................. 21 Figure 15 : SMU connector .............................................................................................................................................................. 22 Figure 16 : CAN connectors on the BMM front panel ...................................................................................................................... 22 Figure 17 : Diagnostic connector ..................................................................................................................................................... 23 Figure 18 : BMM HMI ..................................................................................................................................................................... 23 Figure 19: BMU Operating Modes ................................................................................................................................................... 27 Figure 20 : Limitation of the cell current for continuous charge according to the SOC .................................................................. 30 Figure 21 : Battery charge profile .................................................................................................................................................... 31 Figure 22: Reduction of the cell current limits for continuous discharge according to the SOC ..................................................... 33


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1. INTRODUCTION

This document contains the operating rules for using the Lithium-ion 56V/82Ah battery system.

Applicable documents 1.1.

Ref. Title Reference IR

DR1. CanOpen Dictionary for BMS SDU/SEL/DH/09-0974 Rev J

Reference documents 1.2.

Ref. Title Reference IR

DR2. Synerion 24M Module UM SDU/EEA/DC/11- 0420 Rev. 3

DR3. Battery Management Module UM SDU/EEA/IL/13-0501 Rev. 1

DR4. WinBMS Diagnostic Software UM SDU/EEA/PhL/11-1093 Rev. 4.1

DR5. ESS PV48V_PRODUCTS_ RANGE SDU/EEA/IL/13-1022 Rev 1

Acronyms 1.3.

BMM Battery Management Module BMU Battery Management Unit CAN Controlled Area Network EDU Electrotechnical Device Unit ESS Energy Storage System ESSU Energy Storage System Unit IMD Maximum Discharge Current IMR Maximum Charge Current IMR_C Maximum Charge Current continuous PBIT Power-on Built-In-Test RPDO Receive Process Data Object SDO Service Data Object SMU Safety and Monitoring Unit SOC State Of Charge (battery) SOH State Of Health (battery) TPDO Transmit Process Data Object CONVERTER Converter connected to the battery (not Saft scope of supply)


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2. UNPACKING AND INSPECTION

Check the packing material for any damages before accepting delivery from the carrier. If there is any sign of damage, report it to the carrier and to SAFT and make a “certified letter with acknowledgement” to the transporter.

Figure 1: Battery System

Ensure that 4 kWh battery system (P/N: 774423) is delivered with the following parts:

2 modules Synerion 24M (P/N : 773150) 1 BMM (P/N : 772954-xx)

1 accessories kit (P/N: 774214) composed of: o Power connections :

Between the 2 modules (x1) Between the module and the BMM (x2)

o Communication wires : Between the 2 modules (x1) Between the module and the BMM (x1) The terminal cap on the last module (x1)

o Screws, nuts, washers o External CAN terminator

USB key (Part Number : 773294-xx) : o User’s manuals : BMM, Synerion 24M module, battery system, diagnostic software o Diagnostic software

The variants “-xx” are described in [DR5] in §1.2.


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It is advised to save the original packaging for reuse in case of later shipment.

Figure 2 : Synerion 24M Module

Figure 3 : BMM ESS PV48V


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Battery characteristics 2.1.

The battery is based on a modular architecture using basic modules (Synerion 24M) made of Li-Ion cells in parallel and series. Modules are then connected in series and associated with a BMM (Battery Management Module), which constitute a Battery Unit (ESSU: Energy Storage System Unit). The BMM communicates on one side with both modules and on the other side with the customer calculator (SCU). The customer communication bus use CANopen asynchronous protocol. See Figure 4 below for the battery electrical architecture. The operating characteristics of the battery pack (in 2P7S configuration or 7S2P in accordance to the IEC 62620 standard) are given below:

Main electrical characteristics

Nominal voltage (3.6V / Cell) 50.4 V

Maximum voltage (4V / Cell) 56 V

Minimum voltage (3V / Cell) 42 V

Total battery capacity (C rate, +20°C) (41Ah / Cell)

82 Ah

Minimum battery capacity (C rate, +20°C) (40Ah / Cell)

80 Ah

Maximum charge current (normal charge / accelerated charge)

(Note 1) A

Maximum continuous discharge current 160A (Note 2) A

Maximum peak discharge power (3s) 12 kW

Fuse type 200 A

Mechanical characteristics

Battery Width 483 mm

Battery Depth 371 mm

Battery Height 400 mm

Weight 55 kg

IP IP20

General characteristics

Insulation resistance @ 100Vdc >1 MOhm

Dielectric 500 Vrms

Operating battery temperature range 0°C / +40°C °C

Storage battery temperature range -25°C / +70°C °C

Maximum Relative Humidity 95 (non-condensing) %

Maximum Operating Altitude 2000 m

Table 1 : Battery System Characteristic


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Note 1: The maximum charge current allowed is function of the temperature; see Table 3 in §6.6.3 for more detail. Note 2: The maximum discharge current allowed is function of the temperature; see Table 4 in §6.7.1 for more detail.

Figure 4: Battery Architecture


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3. GENERAL DESCRIPTION

Battery System 3.1.

3.1.1. ESSU Synoptic

The ESSU is composed of 2 Synerion 24M modules, 1 BMM and all the power and communication cables. The ESSU is air cooled by natural convection.

Figure 5 : ESSU overview

Always use the battery modules with the BMM!

Not doing so will affect the performance and the safety of the product and void the warranty.

Example of electrical cabinets containing 2 modules and 1 BMM

Synerion 24M module

Battery Management Module


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3.1.2. Synerion modules

A module is composed of 14 Li-ion cells connected in 2 parallel strings of 7 serial cells. They are assembled in a 19 inches housing according to CEI 60297-2. An electronic board (called SMU board) integrated in the module manages the cells (balancing, sending information such as the end of charge, overtemperature, overcharge, overdischarge, …). The drawing below shows a general view of the module. To get more details, please refer to DR2 (§1.2)

Figure 6 : Module overview

A: Module Electronic Connector (HE10 type) B: Negative terminal C: Positive terminal D: Front panel E: Label

Always use the module with its internal electronic management running. Not doing so will affect the performances and the safety of the product.

B C A

D

E


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3.1.3. Battery Management Module

The Figure 7 below shows a general view of the BMM. To get more details, please refer to DR3 (§1.2).

BMM

SMU

Supply

SMU BUS CAN

Communication

SMU

Module 1

Module 2

SMU

ESSU BUS CAN-IN

Communication

ESSU Diag Bus

+

BMU_V BOARD

FuseContactor

PS

DA

TA

CM

D

RT

N_S

IGN

Vin -

BATT

Vin +

BATT

Vout +

DC network

Vout -

DC network

Current

sensor

ESSU BUS CAN-OUT

Communication

Diagnostic

Communication

Figure 7 : BMM overview

The battery system includes:

2 x 2P7S (either 7S2P according to the IEC 62620 standard) VL41M modules in series (Synerion 24M). Each module is equipped with a safety management unit (SMU) board that provides electronic management and first and second level of protection for the batteries, including:

o Individual cell-voltage measurement. o Temperature measurements of the modules and of its busbar connections. o Cell balancing managed by the BMU. o Alarms and warnings sent to the BMU via the controller-area network (CAN) Bus and

a hardwired “EMERGENCY” signal to protect the batteries if a safety-critical event occurs.

o Communication with the BMU modules via the CAN Bus. o SMU microcontroller sleep and wake-up managed by the BMU. o Self-tests…

One BMM module providing: o Electronic monitoring and protection of the battery string (such as voltage and

current measurements for the battery string during charging and discharging) o Control of electrical distribution unit (EDU) devices (contactor, current sensor, …) o Communication with the customer via the CAN Bus o Information on the state of charge (SoC) and state of health (SoH). o Maintenance via the RS-485 diagnostic interface


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o HMI o Save data and events in a Blackbox

One fuse 200A.

One LEM HASS-200 current sensor.

One EV200 main contactor with auxiliary contacts.

One 3 positions switch to start the BMU

Two fuses 3A to protect the electronics

One DC/DC converter and associated relays in order to power the electronics at 24Vdc

One “Always on” circuit

One precharge circuit

BMM Earthing 3.2.

The steel framework of the BMM is equipped with 1 Earthing point on each side of the BMM. Atleast 1 Earthing point has to be connected to the electrical cabinet frame. The earth continuity between the electrical cabinet and a BMM earth point must be equal to or less than 0.1 ohm and has to be checked once the BMM is installed. The M8 earth terminal is identified on the BMM by the symbol shown at Figure 8.

Figure 8 : Protective Earth symbol

Insulation groups 3.3.

For the BMM, the insulation group’s description is the following:

Group Name Category Signals Maximum

voltage

G1 HV DC circuit

Circuit with non-dangerous voltage not connected directly to

the network (ELV) Power circuit 60VDC

G2 LV DC circuit

Very low voltage not connected to earth (SELV)

CAN bus, trip signal, I/O…

24VDC

G3 Chassis - - -

Table 2 : BMM insulation groups description

The following schematic presents the insulation groups for the BMM:


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Diag bus

CAN

HVIL

Elements électrochimiques

Composants

électrotehcniques

Mesure tensions

et température

éléments

CAN

bus

SMU

BMU

G1G2

LEM

Contacteur

DC bus

Chassis G3

Mesure HV

+ mesure

isolementAlim

Emerge

ncy

Figure 9 : BMM insulation group

Precharge management 3.4.

IMPORTANT: in case the BMM is connected to a converter that contains output capacitors, there is a high risk that the contactor of the BMM is damaged when closing, due to the high inrush current. Prior to connect an external converter to the BMM, be sure that the capacitors of the external devices will not create a high inrush current. These capacitors must be preferably precharged by the converter. The internal precharge circuit is designed with a 100Ω 50W resistor type. The contactor closure time will be according to the capacity value of the application.

Be sure to mention the capacity value to saft in order to adapt the precharge software parameters


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4. MECHANICAL INSTALLATION

Safety rules 4.1.

The safety rules at the beginning of User’s Manual must be respected.

General requirements for the cabinet 4.2.

The cabinet material must be metallic and compliant with ROHS and REACH standards.

The internal painting should be strictly non-flammable and compliant to UL94 V0.

All cabling inside the cabinet must be UL94 V0 compliant.

The cabinet design must be guided towards a good thermal exchange with the exterior to prevent temperature over 65°C in the battery area. A good natural convection path properly sized is sufficient for most of the stationary applications.

The lowest battery module inside the cabinet should be placed at a minimum distance of 80mm from the ground (considering wheels, legs or other) to avoid flooding risks

Cabinet must be IP20 once closed to protect Battery against object penetration and fluid projection.

Cabinet must be IK05 in all sides.

The cabinet must keep its mechanical integrity in case of thermal runaway of one cell. It must resist to a temperature of 650°C during 15 seconds and afterwards a gradual decrease to 25°C at 1°C per second.

Mechanical installation inside the electrical cabinet 4.3.

The stacking or racking of Synerion modules in the horizontal position is the most preferred arrangement for integration in 19” cabinet. The vertical arrangement of battery modules is a configuration that requires specific implementation rules to be supplied by Saft. If the modules are arranged horizontally, the minimal distance between the back of the modules and the rear panel of the cabinet must be at least 25 mm. In the cases where modules are placed in double-side cabinet, the modules have to be placed back to back and a spacing of 50 mm has to be ensured.

To install the BMM in the cabinet:

Verify that the switch of BMM is on the “Off” position and there is no power.

Connect the grounding stud located on the BMM side to the electrical cabinet frame (cf. §3.2)

Insert the BMM inside the cabinet thanks to the 19’’ rack slides. Fix it thanks to 4 M6 Torx screws and 4 Ø6 spring washers. The torque is 8.5±10%N.m.


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Figure 10 : Mechanical installation

To install the modules in the cabinet:

Verify that the modules are equipped of 19’’ adapters (2 per module). If not the case, the 19’’adapters are in the accessories kit. The SAFT reference is 771279.

After installation of 19’’ adapters, install the 2 modules inside the cabinet on the 19’’ rack slides. Use the M6 Torx screws with the Ø6 spring washers to fix them on the 19’’ support. The torque is 8.5±10%N.m.

The details of mechanical interfaces are described in APPENDIX I: MECHANICAL INTERFACES.


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5. ELECTRICAL INSTALLATION

Recommendations prior to connection 5.1.

The connections shall be made by personnel being aware of the safety electrical rules.

Electrical connections 5.2.

Always supply power the BMM only after installation of the BMM and the modules inside the cabinet.

To install the system, follow the instructions below:

Verify that the switch of BMM is on the “Off” position.

SAFT recommend to connect the cabinet to the ground by an earthing braid of 35mm², compliant with the IEC60950-1.

Connect the communication cables between the modules and the BMM in respecting the steps below (cf.Figure 12) :

o Between the SMU connector on the front panel of the BMM and the first module

o Between the modules together

o Cap on the last module

o CAN_OUT connector has to be plugged to a terminal connection ref. P/N 769035.

o CAN_IN connector ensure the communication with the application

Remove first the terminal cover (4 screws) to connect the power cables. The following power connections have to be assembled with a torque of 8.5N.m ±0.5 N.m:

o The power connections between BMM and the modules are made using wires with screw and washers (All provided by SAFT in the accessories kit). The terminals to use are Vin+ BATT (to the positive pole of second battery module) and Vin- BATT (to the negative pole of the first battery module). Be careful because these parts are always energized by the batteries!

o Be careful on the order of the connection of the power cables (cf.Figure 13) :

Between the negative pole of first module and Vin- BATT of the BMM

Between the positive pole of the lowest module and the Vin+ BATT of the BMM

Finally, between the positive pole of the first module and the negative pole of the lowest module


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Replace the terminal cover to avoid contact with the power terminals.

The power cables between the BMM and the application are not provided. The terminals to use are Vout+ DC Network and Vout- DC Network.

Moreover, before using the BMM, ensure that the following connectors have been plugged with the accessories kit supplied by SAFT: SMU connector, CAN connectors, Earth.

Figure 11 : Detail of external BMM connection

Figure 12 : Communication wires

CAN_OUT

Ground

Vin- BATT

Switch OFF/ON/START

CAN_IN

Front panel with screws

Battery modules

power

terminals

Application power terminals

Vin+ BATT

Diagnostic connector

SMU connector

HMI Ground

Vout+ DC

Vout-° DC


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Figure 13 : Power cables

Electronic and software interfaces 5.3.

5.3.1. BMM Power supply

The BMM is started pushing the “Start” position (intermittent third position of the On/Off switch).

Figure 14 : Switch “Start” Position

Start switch

Last connection to be connected


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5.3.2. SMU connector

This connector is located on the front panel of the BMM and enables to power supply the SMU board of the first module on the daisy chain. It allows also to transport the CAN bus of the modules.

Figure 15 : SMU connector

5.3.3. CAN Communication connectors (RJ45)

These connectors are located on the front panel of the BMM and contain the following signals:

Connector CAN_IN : CAN bus connected to the application or other BMM

Connector CAN_OUT: CAN bus going to other BMM. If the considered BMM is at the end of the daisy chain, this connector has to be plugged to a terminal connection ref. P/N 769035.

Figure 16 : CAN connectors on the BMM front panel

1 : EMC_GND 2 : RESET_SMU 3 : GND (0V) 4 : GND (0V) 5 : GND (0V) 6 : EMER_ALARM 7 : V_POWER_SMU 8 : CAN_L_SMU 9 : CAN_H_SMU

DB9 Male

« SMU » connector

SMU connector

1 2 3 4 5

6 7 8 9

1 : CAN_H 2 : CAN_L 3 : GND (0V) 4 : N/U (CAN_IN) / CAN_H_TERM (CAN_OUT) 5 : N/U (CAN_IN) / CAN_L_TERM (CAN_OUT) 6 : EMC_GND 7 : GND (0V) 8 : N/U RJ45

female

CAN_IN connector

CAN_OUT connector


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5.3.4. Diagnostic interface

One diagnostic software (compatible PC using an external USB/RS485 converter) is dedicated for battery monitoring, battery parameters configuration and software updating of the BMU: please refer to DR4 (§1.2). The connector is located on the front panel of the BMM and enables to communicate with a PC using the SAFT diagnostic software. The battery diagnostic port is a RS-485 serial link. Use a “RS-485 to USB” converter to connect to the USB port of the PC.

Figure 17 : Diagnostic connector

The diagnostic software is delivered on a USB key (P/N: 773294-xx). Caution: contact Saft for the definition of the harness connecting the diagnostic connector to a RS485/USB converter.

5.3.5. HMI

Figure 18 : BMM HMI

1 : RS-485_+ 2 : RS-485_- 3 : CAN_L 4 : CAN_H 5 : GND (0V) 6 : 24Vdc (BMU) 7 : N/U 8 : CAN_L_SMU (Saft only) 9 : CAN_H_SMU (Saft only) DB9 Female

« Diagnostic » connector

Diagnostic connector

LED1 LED2 LED3 LED4

Push button


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Push button not activated: LED: 1 2 3 4

Orange-Steady

Minor alarm (warning)

Red-Steady Major alarm

Green-Fast blinking (0.1s) Charge

Green – Slow blinking (0.6s) Floating

Green-Steady Discharge

Push button activated less than 3 seconds: SOC LED: 1 2 3 4

Steady SOC > 60%

Steady SOC > 40%

Steady SOC > 20%

Steady SOC ≤ 20%

Push button activated more than 3 seconds: SOH LED: 1 2 3 4

Blinking SOH > 75%

Blinking SOH > 50%

Blinking SOH > 25%

Blinking SOH ≤ 25%

SOH: gives an indication of the state of health of the battery. SOH = 100% at beginning of life. SOH=0% at end of life (typically after 30% of capacity loss).


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6. OPERATION DESCRIPTION

General principle 6.1.

Charge and discharge of the Li-ion battery must be monitored and managed with respect to physical parameters such as cell voltages and module temperature. This management is performed by the BMU_V board, which runs algorithms and monitors the battery. The concept is to use the features of the converter to perform the battery management. The application will receive data from the battery via CAN bus and must take the appropriate actions. Safety functions will still be ensured at the ESSU unit level by the BMM.

The switch must be in “OFF” position when battery is not used Due to the architecture, electronic boards remain powered if the switch is in “ON” position,

accordingly the battery will continue to discharge on the consumption of its own electronics

Safety functions inside the BMM 6.2.

The BMM contains the devices required to ensure protection against safety hazards: Fuse: 200 A Fuse (for +) enable to protect the battery system against over-current and short-circuit. Contactor TYCO Kilovac EV 200:

o Ensures protection of the battery against critical events. This contactor is controlled by the BMU_V board.

o See the fault codes table in DR1 (§1.1) or in APPENDIX II: Fault codes and alarm list of the battery system.

For the contactor control, several options are possible:

The BMM requests the closing and the opening authorization to the client

The BMM requests only the closing authorization to the client

The BMM requests only the opening authorization to the client

The BMM is autonomous for opening or closing the contactor

These options are configurable and must be requested at Saft prior to order the battery system. See [DR5] in §1.2 to know the contactor driving in according to the battery system part-number.


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CAN bus 6.3.

If the BMM is not chained with other BMM, a terminal plug (P/N 769035) has to be connected on the CAN_OUT connector. That will activate the 120 Ohms termination resistor inside the BMU_V board. This CAN bus allows the application to get information on the status of the battery (SoC, temperature, faults…) and to control it (depending on the contactor control described in §‎6.2). Few options available:

Protocol: CAN Open asynchronous

Speed: 100, 125, 250, 500 and 1000 kb/s.

Please refer to DR1 (§1.1) for more information about the CAN protocol.

Battery system start-up and shutdown: 6.4.

The BMU logic controller requires a +24VDC power supply, by means of a DC/DC converter.

The battery system is started up by: o Switching the “On/Off/Start” switch to the “On” position. o Pushing the “start intermittent switch” for a second or apply 48VDC on the application

power terminal. o After performing successfully its self-tests – the power-up built-in test (PBIT) and the

initiated built-in test (IBIT) – the BMU requests or not permission (depending on the contactor control described in §‎6.2) to the application in order to close the main contactor to allow operation; however, it will close the “Always On” circuit

The battery shutdown: o Switch to “Off” position will deactivate the “BMU”. o The BMU requests or not permission (depending on the contactor control described

in §‎6.2) to the client in order to open the main contactor. If the client does not give the authorization, the BMM will open the contactor by itself after 5 seconds.

o As the consequence, the battery will go to “after run” mode and will perform its Poffbit self-tests.

o After successfully performing its self-tests, the BMU deactivates the “self-power relay” which switches off the DC/DC converter and open the “Always On” circuit.

o Then the battery will go to sleep mode. If the PBIT tests fail, the BMU goes into Safe mode while waiting for a hardware reset or a self-reset to restart the test and to switch to Nominal mode (charging or operating). For more information on the BMU operating modes, please refer to the next section. The battery system will only start up if the BMU is powered up and awake.


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Battery system States/Modes: 6.5.

The BMU operating modes are described in the sections below:

Figure 19: BMU Operating Modes

Critical fault detected, either by software or hardware channel

BMU is supplied AND BMU_enable = 1

Software reset occurred

BMU supply turned off

BMU_enable = 1

BMU is supplied AND [BMU_enable = 1]

After run completed and POffBIT ended successfully

[Contactors opening is allowed by the client AND BMU_enable = 0].

Contactors opening is allowed by the client OR end of discharge is reached

Contactors closing is allowed by the client

PBIT ends successfully while contactors closing are allowed by the client

PBIT ends successfully

INIT

NOMINAL

SAFE

AFTER RUN

STAND BY

SLEEP

BMU_enable = 0

POffBIT failed

Hardware reset occurred (BMU_enable turned to 0)

PBIT failed

Off


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6.5.1. Off Mode:

In this mode, the BMU does not monitor the battery system, as it is not powered up or awake. This is the mode where the battery is completely shut down.

6.5.2. Init Mode:

In this mode, the battery pack is not yet operating (it is isolated from the 48Vdc power network). The BMU is powered by switching the “On/Off/Start” switch to the “On” position and either pushing the “start intermittent switch” for a second to launch the following operations or either by applying 48Vdc on the application power terminal. During the Init Mode:

1. Software initialisation 2. The PBIT self-tests (launched every time that the BMU is powered up or after a reset).

6.5.3. Standby Mode:

In this mode, the battery pack is not yet operating (it is isolated from the 48Vdc power network). PBIT self-tests are successful and the BMU requests or not permission (depending on the contactor control described in §‎6.2) to the client in order to close the contactor to allow operation. However the BMU will close the “always On” circuit.

6.5.4. Safe Mode:

Two kinds of faults can occur: warnings and alarms. At warning level, the battery system stays in nominal mode and only informs about the fault. If a fault occurs with an alarm level, the contactor is eligible for opening. Depending on the contactor control described in §‎6.2, the contactor can be opened either by client authorization or directly by the BMM. If the client does not the authorization, the BMM will open the contactor by itself after 5 seconds. In this mode, charging and discharging (operation) is not permitted. However, the BMU module remains operational (powered up and awake), as well as the “Always on” circuit. A self-reset, a software reset (please refer to DR1 in §1.1) or a hardware reset causes the BMU to go into Nominal mode again.

6.5.5. Nominal Mode:

The Nominal Mode corresponds to the module charging or discharging. These two operating modes are completely transparent to the BMU and represent a single Nominal Mode.

o Charge or Operation:


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The user closes the enable switch (“On” position) and activates the intermittent switch (“Start” position). The BMU starts up in Init Mode and then, having passed its test sequences and initialised software, switches to Stand-by Mode. The BMU then closes the contactor, or requests permission to do so from the client via the CAN Bus, to enter in the Nominal Mode. Under these conditions, the BMU performs several functions (such as monitoring and protection of the battery modules, communication with the various (ECU and SMU) modules, managing the contactors and managing battery cell balancing). If the PBIT self-tests fail at start-up or first or second level of safety events occur, then the BMU goes into Safe Mode and waits for a (software or hardware) reset or a self-reset to go back into Init Mode and then into Nominal Mode.

6.5.6. After-Run Mode:

This mode occurs after Nominal Mode (charging or operating); the BMU performs its “POFFBIT” self-test, as for example, it tests for the contactor opening by checking the contactor auxiliary contact. In this Mode, the BMU remains operational (powered up and awake). The paragraphs below describe the transition between Nominal Mode and After-Run Mode.

o Operation or ChargeAfter Run: The operator turns the enable switch of the BMM to the “Off” position. The BMU remains powered by the DC/DC converter, due to the “self-power relay” (activated by the BMU). Itlaunches the “POFFBIT” test and sends a set point to the SMU boards so that balancing can be maintained and managed during a specified period (30 minutes maximum), as long as there is no safety-critical event (in which case the BMU goes into Safe Mode). Once the “POFFBIT” test has been passed, the BMU opens the main contactor or requests permission to do so from the client (§6.2 on contactor control), then the BMU switches off the self-power relay and then the DC/DC converter is not powered anymore. If the “POFFBIT” test fails, then the BMU goes into Sleep Mode and stays there for a certain time before going into Off Mode.

6.5.7. Sleep Mode:

This is the mode where the BMU microcontroller operates in its “low power” state, as do the SMU boards; the main contactor is open. Transitions between BMU operating modes are controlled as per the Figure 19.


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Battery charging 6.6.

6.6.1. Functioning

The BMM sends to the application via the CAN bus the maximum continuous charge current allowed (IMR_C). The application must ensure this value is never exceeded. Exceeding this value might lead to an unsafe use of the battery as well as a preliminary aging. During charge, the BMM controls the battery parameters (cell voltages, current and temperature) and informs the application about some warning first and then alarms. IMR_C depends on 2 parameters:

o battery temperature : to ensure the battery life time o battery SOC : IMR is decreased to 10% between 90 to 100% of SOC to limit the voltage

Figure 20 : Limitation of the cell current for continuous charge according to the SOC

6.6.2. Overcharge protection

In case where the charger does not respect the current limit, the BMM will detect overcharge conditions. There are two levels for such a situation. The first level (one cell voltage > 4,05V) only implies a warning (fault n°7) sending on the CAN bus. In case the converter continues charging the battery and one cell reaches the second level (one cell voltage >4,13V), the BMM will send an alarm (fault n°8) and will ask to the application (depending on the configuration) for opening its battery contactor and in any case, by itself, after few seconds. The SMU board can also send an independent signal (Emergency) to the BMM that will open the main contactor.

0

20

40

60

80

100

120

0 20 40 60 80 100 120

SOC [%]

% IMR_C


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6.6.3. Charge profile description

The charge consists in a CC/CV (Constant Current / Constant Voltage) charge type. - The maximum continuous charge current IMR_C and the maximum dynamic charge

current IMR depend on the temperature according to Table 3. Both of them are sent on CAN bus.

- The maximum charge voltage VMR is sent on CAN Bus. Nevertheless, it is possible to charge the module with a lower value, the available capacity will be therefore smaller.

- The battery can be let in “floating” charge during phase 3.

Figure 21 : Battery charge profile

The following tables give the recommended maximum currents for the normal and accelerated charging profiles as a function of temperature, for a VL41M cell. Note: IMR values are related to 5s pulse.

Table done according to cell research library V3.0

Normal charging profile:

Temperature (°C) -30 -25 -20 -10 0 10 25 45 50 55 60 IMR_C (A) 0 14 18 26 38 54 82 82 82 40 0

IMR (A) 0 44 54 82 120 120 120 120 120 120 0

Table 3: Normal Charge for the battery system

VMR

IMR limit sent on CAN BUS by BMM IMR_C limit sent on CAN BUS by BMM VMR limit sent on CAN BUS by BMM Battery voltage Charger current

Time

1 2

3

IMR_C

IMR


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6.6.4. End of charging

The end-of-charge phase is the additional gradual charging period that restores battery capacity to around 80-95% (the threshold depends on the VMR voltage). Under normal charging conditions and if the battery modules are perfectly balanced, the end-of-charge occurs when the current drops below 1A while the charger voltage is maintained. In fact, when the battery pack is only drawing a small current (less than 1A), the charger can stay connected indefinitely, with no risk of damage to the battery, in order to:

Maintain the battery in its optimum charge state and compensate for self-discharge, i.e. the tendency to discharge over time even when not under load.

Allow chargers to operate as a power supply in a “parking, maintenance” mode: if the

inverter is active, the charger supplies the power required up to its maximum power, beyond which the battery supplies the remainder.

Battery discharge (operation) 6.7.

6.7.1. Functioning

The BMU transmits the permitted maximum discharge current (IMD) via the CAN Bus in real time. This value depends on three factors:

The discharge current during the last few minutes.

The maximum temperature of the modules.

The battery pack’s state of charge (SoC).

The system logic controller must ensure that the discharge current never exceeds the value received on the CAN Bus. The maximum speed of variation of the IMD set point can be set as a parameter; its default value is 10A/s. IMD as a function of maximum module temperature: It should be noted that this function reduces the discharge current thus preventing sudden contactor opening in the event of battery overheating. IMD as a function of SoC:

6.7.2. Discharge protection

During a discharge if one cell reaches Umin=2.7V, the BMM will send a warning (code fault n°9) and the converter has to stop the discharge. If the discharge is continued and one cell reaches Umin=2.5V, the BMU will send an alarm (code fault n°10) and open the main contactor. The SMU board can also send an independent signal (Emergency) to the BMM that will open the main contactor.


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6.7.3. Discharge profile description

Figure 22: Reduction of the cell current limits for continuous discharge according to the

SOC

It should be noted that this function reduces the discharge current thus preventing sudden contactor opening in the event of battery cell under voltage. Note: Max values are related to 5s pulse and limited at 300A during 3s.

Table done according to cell research library V3.0 Normal discharging profile:

Table 4: Normal Discharge for the battery system

Alarms and warnings 6.8.

The BMM sends on the CAN bus the code faults (warnings or alarms) to the application (as described in the CAN bus specification DR1 in §1.1 or in APPENDIX II: Fault codes and alarm list of the battery system). For example, during a discharge if one cell reaches Umin=2.7V, the BMM will send a warning (code fault n°9) and the converter has to stop the discharge. If the discharge is continued and one cell reaches Umin=2.5V, the BMU will send an alarm (code fault n°10) and open the main contactor.

0

20

40

60

80

100

120

0 20 40 60 80 100 120

% IMD_C

SOC [%]

Temperature (°C) -30 -25 -20 -10 0 10 20 50 55 60

IMD_continuous (A)

0 116 142 160 160 160 160 160 150 0

IMD_Max (A) 0 232 286 300 300 300 300 300 300 0


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Balancing 6.9.

The balancing of the cells consists in keeping the cell voltages homogeneous in all the system. The resistive balancing management circuit is integrated into the SMU board. The management is done by the SMU microcontroller (equalizing cells voltages) following BMU settings (overall cells voltage target) transmitted permanently via the CAN Bus. This circuit equalises cells voltages. It partially discharges any cell that exceeds the specified voltage discrepancy with respect to their neighbours via bypass resistors. The balancing is done only if the cells are unbalanced and if their voltage is above 3.5V. Balancing operates during all states when the BMM is power supplied.

Data exchange from BMM to application controller 6.10.

All the data from BMM are sent to the application controller, on the CAN bus. Here below are defined the main data for customer use. A more detailed definition is described in DR1 (§1.1).

o Battery voltage: sum of the cells voltages in series inside a battery unit. o Battery current (positive current : charge, negative current : discharge) o Battery system state (refer to Figure 19) o Battery contactor status (main contactor open/closed) o Min/Max cell voltages from the battery unit (allows identifying which cell in which module is

min or max voltage) o Min/Max temperature of the battery unit (allows identifying which module is at min or max

temperature). o Maximum current available in charge / discharge (IMR/IMD): depends on SOC,

temperature, current and time. o Battery State Of Charge without SOH: gives the available capacity of the battery without

taking into account the SoH. For example, if the battery is new and can store 30Ah, this SoC will be at 50% when there is 15Ah left in the battery.

o Battery State Of Health: represents the ageing. It is based on number of cycles, SOC and temperature during the battery life. The SOH is equal to 100% for a fresh battery, and 0% when the battery has reached its end of life (e.g. loss 30% of its capacity) :

- For a new battery, SOH=100% - For a battery that lost 1/3 of its capacity, SOH=0%

o Battery State Of Charge with SOH: gives the available capacity of the battery taking into account the SoH. For example, if the battery is new and can store 30Ah, this SoC will be at 50% when there is 15Ah left in the battery. After aging, if the battery can store only 20Ah, the SoC will be at 50% when there is 10Ah left.

o Code faults: for meaning and reactions see table in APPENDIX II: Fault codes and alarm list of the battery system.

o Self-test : - Self-test required: indicates that a self-test will be started in [Self-test_time] seconds

minimum after sending this object (PBIT). - Self-test in progress: indicates that a self-test is in progress (PBIT or IBIT).


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o BMU watchdog: oscillates between 0 and 1 at each frame emission (so cycle is 200ms). It indicates the battery system software is working properly. If the application controller stops seeing the oscillation, the system has to stop using the battery.

o SoC Threshold : 2 levels of warning to inform the client that the SoC is below a defined value

o Battery identification: this frame allows identifying precisely the system, its configuration and the software versions.

Data exchange from application controller to BMM 6.11.

All the data from the application controller to the BMM are sent on the CAN bus. Here below are defined the main data for customer use:

o Error reset: when setting the appropriate bit from 0 to 1, the error is reset (if the fault condition has been resolved)

A more detailed definition is described in DR1(§1.1).


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7. HANDLING & STORAGE

This paragraph describes the handling and the storage of the battery or its components.

Handling 7.1.

For each handling operation, make sure that the battery is shutting down.

Storage 7.2.

Long storage of the battery or the module at a too low SOC will lead to a deep discharge and in consequence to a damage of the module. Please read carefully the storage instruction below.

Synerion modules are shipped from Saft facility at a SOC of 50% ensuring 5 months storage time at 40°C (including transport period). It is required to store the module indoors in its original packaging on a dry and clean surface.

Initial SOC 10% > 20% > 40% 50% >60%

SOC displayed

Ah 4 8 16 20 24

Days @20°C

43.1 86.1 172.3 215.4 258.4

Months @20°C

1.4 2.9 5.7 7.2 8.6

Months @40°C

1.0 2.1 4.1 5.1 6.2

Table 5 : Storage duration

Saft recommend to check the voltage of the module or the SOC of the battery and to perform a recharge if necessary prior and after any long distance shipment or long storage period to avoid any risk of damage due to a possible uncontrolled storage conditions (§7.2.2).

If an undervoltage is detected (warning or alarm), the battery should be recharged in the following 7 days to avoid that the cell voltage drops below 2V.


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If a cell voltage drops below 2V, the SMU board will activate its emergency alarm. Do not try to recharge the module and contact Saft.

7.2.1. Storage location

It is required to store the battery indoors in a dry, cool location, lower than +40°C on open shelves in order to preserve the lifetime of the cells. Storing the battery at a temperature between 15°C and 30°C will allow extended shelf life duration.

7.2.2. State of charge checking

Module is shipped with state of charge of 50% ensuring 5 months of storage at 40°C. Check periodically and at least every month the battery or module voltage with a voltmeter on the (+) and (-) poles. Make sure that the module voltage is between 25.4V and 28V. If the module is less than 25.4V, charge the module as specified in APPENDIX III: CHARGE THE MODULE IN STORAGE.

NEVER RECHARGE A MODULE INDIVIDUALLY Failing to strictly comply with the storage and maintenance recommendations voids the warranty.

8. MAINTENANCE

Except the voltage control during storage, no special maintenance is required on the electrochemical cells. The Maintenance Manual describes the possible maintenance operations (safety instructions, battery recharge, preventive and corrective maintenance, troubleshooting…) In case of malfunctioning or if the battery or modules has been exposed to abnormal conditions (crushes, short-circuit, overcharge, overheat, electrolyte leakages on cells…), contact SAFT. It is the responsibility of the customer to ensure that maintenance people have the skills to operate on low voltage systems (ELV). It is It is strictly forbidden to open the unit prior to Saft’s formal approval.


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9. PACKAGING AND TRANSPORT

The lithium-ion batteries are restricted for transport according to UN Recommendations of Dangerous Goods Transportation (UN 3480 when shipped alone and UN3481 when shipped inside equipment). Packaging preparation for transport and shipment must comply with the appropriate applicable regulations such as IATA (Air), IMDG Code (Maritime), ADR (Road in Europe) rules. This chapter intends to give an overview of the procedure but it is the responsibility of the customer to follow and stay informed of the last regulation evolutions. In addition, countries that are not part of the ADR (European road transport), IATA (International air transport) or IMDG (Sea transport) could have their own requirements.

Battery classification 9.1.

Shipment name: Lithium-Ion batteries UN classification: UN3480 Class 9

Training 9.2.

People engaged in the transport of dangerous goods shall receive training in the contents of dangerous goods requirements commensurate with their responsibilities. Refer to UN regulations for more details.

Battery packing 9.3.

The batteries must be transported in a packaging conforming to the UN regulations. A completed package must display a Class 9 hazard label in addition to markings that identify the applicable proper shipping name (Lithium ion batteries) and UN number (3480). It is advised to save the original packaging for reuse in case of later shipment.

Charging state for transportation 9.4.

The battery can be charged at the level required for certain storage duration.

Documentation for transport 9.5.

The following documents must be prepared for transportation:


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A shipper’s Declaration for Dangerous Goods.

Safety instructions ( SAFT uses the MSDS NS 710 051)

If transport by air and weight exceeding 35kg, a copy of the approval by the state of the origin must accompany the consignment.

If transport by air of a prototype or small series, a copy of the approval by the state of the origin must accompany the consignment.

10. DISPOSAL

At the end of life, the battery pack has to be returned to a designed collecting centre for recycling. Please contact your Saft commercial support before shipment. For transportation, apply the following rules as a minimum:

Discharge the unit(s). Use a packaging conform to UN regulations. Pack the unit(s) in a way to avoid any risk of short-circuit between the terminals or

the unit(s). It is recommended to individually pack each unit in a plastic bag. Do not store close to a heat point. Keep the packaging in a dry place. Use a strong packaging to handle the weight of the products. Design the packaging to avoid internal moves during transportation or handling. Correctly identify the packaging at the outside with the type and the quantity of

unit(s). If possible, use the original packaging.

For updated disposal information, please connect to SAFT web site.


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APPENDIX I: MECHANICAL INTERFACES



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APPENDIX II: FAULT CODES AND ALARM LIST OF THE BATTERY SYSTEM

Warnings are indicated in white color / Alarms are indicated in red color.

Fault n° Description Activation Condition Reset level SAFT action Comments

1 Redundant safety events

signaled by the SMU modules

Emergency redundant hardware channel is active

during 3000ms Reset ON/OFF Contactor opening

2 Battery contactor activation on

short circuit (fuses blown)

[Battery current > 300A] OR [Voltage difference between

cells sum and fuse measurement > 10.000V]

during 3000ms

Customer Reset / Reset ON/OFF

Contactor opening

3 A module is going over temperature – 1st level

Module temperature > 50°C during 1s

Autorestable / Customer Reset /

Reset ON/OFF

4 A module is over temperature

– 2nd level Module temperature > 60°C

during 1s


Reset ON/OFF Contactor opening

5 A module is going under temperature – 1st level

Module temperature < -20°C during 1s


Reset ON/OFF

6 A module is under temperature

– 2nd level Module temperature < -25°C

during 1s





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7 A cell is going over charge –

1st level Cell voltage > 4,05V during 5s


Reset ON/OFF

8 A cell is over charge – 2nd

level Cell voltage > 4,13V during 5s



9 A cell is going under voltage Cell voltage < 2,7V during 5s Autorestable /


10 A cell is under voltage Cell voltage < 2,5V during 5s Customer Reset /


11 Cell voltage out of range If at least one cell has a voltage

out of range during 5s



12 Too many modules with out of

range temperature

The number of modules with out of range temperature is

greater than 1 during 1s



13 One Tconnect is out of range One connection temperature < -

29°C or > 115°C during 1s



14 CON+ voltage out of range CON+ voltage < 15V or > 32V

during 0,5s


Reset ON/OFF

15 High BMU supply voltage BMU supply voltage >32V

during 0,5s


Reset ON/OFF



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16 Battery 12V supply is low BMU supply voltage < 8V

during 0,5s


Reset ON/OFF

17 Battery contactor status not

expected (opened)

Inconstency between contactors command (close)

and real contactor state (opened) for 2s


Reset ON/OFF

18 Battery contactor status not

expected (closed)

Inconstency between contactors command (open)

and real contactor state (closed) for 2s

Autorestable / / Reset ON/OFF

Contactor opening

19 Over current in charge Measured charge battery

current > MAX(2.000 x IMR ; 20.000) during 2s


Contactor opening

20 Over current in discharge Measured discharge battery current > MAX(1.200 x IMD ;

20.000) during 2s


Contactor opening

21 SOC invalid SOC calculation detected

invalid


Reset ON/OFF

22 SOH invalid SOC calculation not updated

after 72h


Reset ON/OFF

23 Battery 24V supply is low BMU supply voltage < 16V

during 0,5s Autorestable

24 Fuse blown Fuse blown detected during

more than 3s





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25 Charge current discrepancy –

1st level

Measured charge battery current > MAX(1.200 x IMRc ;

10.000) during 2s


Reset ON/OFF

26 Charge current discrepancy –

2nd level

Measured charge battery current > MAX(2.000 x IMRc ;

15.000) during 2s


Reset ON/OFF

27 Over scattering on cell resistance – 1st level

Number of cell internal resistance scattering is over

warning level


Reset ON/OFF

28 SOC not adjusted during the

required time SOC not adjusted for more than

1 month


Reset ON/OFF

29 SMU communication problem At least one SMU allocation has

failed more than 3 times


Reset ON/OFF

30 SMU re-connection failed Number of reconnection

attempts exceeds 3 for one SMU



31 A module connection is going

over temperature Maximum connection

temperature > 80°C during 1s


Reset ON/OFF

32 A module connection is over

temperature Maximum connection

temperature > 90°C during 1s



33 Battery current sensor out of

range (lost)

Battery current is out of range during 2s OR [Main contactors opened AND [battery current >


Reset ON/OFF



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2.000A OR < -2.000A]] during 2s

34 Autotest failure

If Built-In-Tests (PowerON, Continuous, Initiated,

PowerOFF) failed (it is considered as failed after 3

consecutive unsuccessfull tries)



35 Pre charge failure

If battery contactor voltage is too high during a specific time atfer the closing order of main precharge contactor OR if a contactor is open while its command is to be closed

Autorestable Contactor opening

Be sure to mention the capacity value to saft in order to adapt the precharge software parameters

36 IBIT undone for 6 months 6 months passed since the last

IBIT



37 Inconsistent temperatures Maximum module temperature

gap > 10°C during 1s


Reset ON/OFF

38 Low SMUs supply voltage If powerSMU supply is enable

and if powerSMU is not detected for 0,2s





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39 Unbalanced cells

[NewSocMaxCalculate = 1 (soc refreshed)] AND [minimum SOC

> 50%] AND [cell voltage difference > 100mV] AND

[minimum cell voltage > 3,5V for 5s]


Reset ON/OFF

40 Over scattering on cell resistance – 2nd level

Number of cell internal resistance scattering is over

alarm level



41 Communication to client lost

CAN message not received correctly by the BMM during a timeout depending on the CAN

baud rate.


Reset ON/OFF

42 Invalid total cell number

encountered If the total number of cells is not

equal to 28 cells Reset ON/OFF Contactor opening

43 Invalid SMU software version

number encountered If all software versions are not

the same Reset ON/OFF Contactor opening

44 IMD/IMR from algorithm are

invalid

If the IMD/IMR calculation function is in error state and

reinitialization failed


Reset ON/OFF

45 Microprocessor cycle

overtaking or cycle error

Software cycle duration is greater than expected duration

(according to the mode) Reset ON/OFF Contactor opening


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APPENDIX III: CHARGE THE MODULE IN STORAGE

General

o For the first charge or after any storage period longer that one month, the module cells might be unbalanced.

o The balancing of the cells consists in keeping the cell voltages homogeneous in all the system. It is automatically performed if the voltage > 24.5VDC.

Check the voltage on the storage module

o Check periodically (every 2 months) the voltage and charge if necessary.

o Measure the voltage with a voltmeter on the (+) and (-) poles of the module battery.

o Make sure that the module voltage is between 25.4V and 28V.

o If the module is less than 25.4V charge the module as specified here below.

Charge the module

CAUTION: NEVER RECHARGE A MODULE INDIVIDUALLY.

CAUTION: IF A CELL VOLTAGE DROPS BELOW 2V THE SMU BOARD WILLACTIVATE ITS EMERGENCY ALARM, DO NOT TRY TO RECHARGE THE MODULE AND CONTACT SAFT. CHARGING AN OVER DISCHARGED MODULE MAY LEAD TO AN UNCONTROLLED HEATING.

o Replace a module in the system by the uncharged module

o Storage the removed module (§7.2).

o Once the BMM is power supplied, it will automatically charge of the cells (§6.4)

o It will require roughly 24h per month of storage to have all the cells balanced.

NOTE: The battery system is operational even if the cells are not balanced, the impact

being that the autonomy is not at full performance during the first days.

NOTE: In case of modules stored at negative temperature, they have to be stored 24h inside an area with a temperature > 0°C (32°F) prior to recharge them.

lithium-ion 4kwh battery system ess pv48v 774423 56 v / …...ess pv48v lithium-ion 4kwh battery...

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