Saft evolion Technical Manual
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Saft evolion Technical Manual

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Summary of Contents for Saft evolion

  • Page 1 Evolion ® Li-ion battery Technical manual...

  • Page 2: Table Of Contents

    Contents 1. Introduction 2. Electrochemical principles 3. Evolion construction Module characteristics Interface features Main functional features Front cover features 4. Evolion operation Application summary The electronic switch (mosfets) Operating modes Internal electronic load Internal heater Cell balancing System level and cell level current interrupt devices...

  • Page 3: Introduction

    The Evolion is a Li-ion battery system. The battery system or module includes two main parts, a Li-ion cell pack and electronics. Both combine together to make a smart battery module. The module operates in a single package and as a standalone 48 Vdc unit. It can communicate to/from the application (dry contact signal and RS485 transmission bus) and can report its status using the user friendly Saft DiagWinBMS communication kit.

  • Page 4: Evolion Construction

    Overcharging will not occur with Li-ion technology. Once the cell is fully charged, an insignificant amount of charge current will be accepted by the cells. The Saft NCA lithium ion cell is sealed and does not produce or exhaust any gases during normal operation.

  • Page 5: Module Characteristics

    3.1 Module characteristics Parameter Value Typical capacity @ C/8 A and 25ºC 77 Ah Rated capacity @ C/8 A and 25ºC 74 Ah Rated capacity @ C/5 A and 25ºC 73 Ah Rated capacity @ C/24 A and 25ºC 79 Ah Width 216 mm (8.50 inches) equivalent to 5 RU Depth...

  • Page 6: Interface Features

    They provide SOC information when the SOC button is pushed. This button toggles the Evolion module OFF or ON. When OFF no LED’s are lit and the unit remains in sleep mode.

  • Page 7: Main Functional Features

    Important: If the power terminals are reverse connected to the rectifier output the battery will not start. If the ON/OFF button is forced to start the Evolion ON, then alarm 27 and 47 will activate and the Evolion will be in safe mode.

  • Page 8: Evolion Operation

    Evolion is placed should have a minimum protection index of IP55. The Evolion discharges with rates equal to 2 hours of autonomy and higher runtimes. It re-charges fully in 3 to 24 hours (from a full discharge).

  • Page 9: The Electronic Switch (Mosfets)

    4.2 The electronic switch (mosfets) The Evolion operates with 6 modes. The modes are invoked by controlling the state of an electronic switch circuit (combined with diodes). The switch circuit is located on the BMST power board. The electronic switches are acted on by the BMST microcontroller or the redundant hardware safety chain.

  • Page 10: Operating Modes

    LED’s do not operate. There is no output voltage on the terminals. 4.4 Internal electronic load An internal electronic load keeps the Evolion’s automatic functionality alive. There are two scenarios, i.e., sleep mode and all other modes. The low power consumption is supplied from the 48 Vdc circuit.

  • Page 11: Internal Heater

    In sleep mode, while the Evolion is in storage, cell balancing occurs automatically. Every hour, the system automatically checks if the balancing process needs to be activated. This feature allows the Evolion to begin normal operation in the application, even after a long storage period, without the need to do an equalization charge.

  • Page 12: Safety Limits During Operation

    Important note: If the redundant 75 Amp fuse ever opens (tertiary protection), the unit must be replaced. Important note: If an Evolion module is exposed to 130 Amps or more of discharge load or re-charge current, even for a short time, the mosfets on the BMST power board may be damaged if the 60 Amp replaceable fuse doesn’t act.

  • Page 13: Module Self Test During Startup

    Memory check invalid (Safe mode and Alarm 47) The duration of the self-test takes less than 3 seconds. Each parallel module in an Evolion battery bank may not start and finish the self-test at the same time. In that case, a “soft start” or “ramp in” feature on the rectifier output is useful. This feature helps to prevent one Evolion (the first to complete its self test) from bearing all the output charge current.The battery will not operate until the self-test...

  • Page 14: Normal Operating Voltage Limits

    The operating voltage must be higher than 49 Vdc to keep the cell balancing circuits active during re-charge. The typical float voltage range is 54.6 (86% SoC) to 56.0 Vdc (100% SoC). The maximum State of Charge (SoC) of the Evolion is directly proportional to the charge set point voltage.
  • Page 15 The discharge characteristics at different temperature are show in Figure 7. The factor affecting these characteristics is the internal impedance of the cells. Note: The internal heater maintains the Evolion’s internal temperature higher than 10 ºC. Discharge curves at less than 10 ºC are for information and not representative of normal operation mode.

  • Page 16: Discharge Performance Factors

    7.1 Discharge performance factors The Evolion has a rated capacity and energy based on a fully charged battery at 56 Vdc and at 25°C (77°F) when discharged at the 8 hour discharge rate for 8 hours of runtime to a 42 Vdc cut-off. When conditions deviate from this, the available capacity on discharge is affected and can be accounted for by the following derating factors.

  • Page 17: Maximum Discharge Current

    7.2 Maximum discharge current A maximum discharge current is defined for the Evolion module. This maximum level optimizes the useful life of the Evolion and particularly for frequent cycling applications. If the maximum re-charge current (with some included tolerance) is ever encountered by a module, it will automatically stop the discharge (alarm #24) from continuing by opening the electronic switch (mosfet).

  • Page 18: Maximum Re-Charge Current (Imr)

    (see Float mode). During re-charge and until it is fully charged, the Evolion accepts charge current with close to 100 % coulombic efficiency. It is the same efficiency at all operating temperatures. The maximum SoC it will attain is equal to the set point voltage (see chapter Open Circuit Voltage (OCV) as a function of State of Charge (SoC)).
  • Page 19 However, for applications using only one installed Evolion and where cycling is infrequent (once per week or longer interval), if operating with IMR, it should avoid the charge regulated mode since a re-charge current margin factor is used in the Evolion.

  • Page 20: Power System Set Points

    The re-charge time needed depends on the %DOD, available charge current and re-charge mode (charge regulated or fast charge). For the charge regulated mode, a minimum of 24 hours is required for re-charge of the Evolion, from a full discharged state. In charge regulated mode, the current accepted by the Evolion is approximately 4 Amps.

  • Page 21: Heat Sink Dissipation In Charge Regulated Mode

    When integrating the Evolion in the application make sure to avoid obstructing all of the vent ports. It is recommended to discuss venting strategy with your Saft representative in order to conclude on the need to implement venting channels and suppression systems. See more details in the chapter Cell Venting in operation.

  • Page 22: Cell Venting In Operation

    Evolion to an unsafe state to vent. Based on history and experience, the only mechanism that would cause a cell to vent and release gas is an internal cell short.
  • Page 23 The higher the %DOD the lower the expected life and vice versa. Since these factors vary greatly between applications, the Evolion’s life expectancy is expressed in calendar life and in cycling life, separately. In that case, the cycling life is given and is independent of the temperature and %SOC. In the same way, the calendar life is given and is independent of level of re-charge current and %DOD in cycling.
  • Page 24 The Evolion includes a State of Health (SOH) alarm (Alarm 53) feature. The SOH at the beginning of life is 100 % and it is equal to the Evolion having 100 % of its capacity available when fully charged. At the end of its life, the SOH signal is 0 % and it is equal to the Evolion having 70 % of its beginning of life capacity.
  • Page 25 The Evolion communicates both a dry contact signal (alarming) and on an RS485/Modbus network as a slave. For alarming, each Evolion module measures and controls its own alarm output signal. The alarm output signal is given both by the LED’s and the RJ45 connectors on the front face. A complete list of alarm signals and troubleshooting guidelines are included in Appendix E.

  • Page 26: Massive Paralleling

    Since the Evolion operates stand alone and is not limited by an external BMS, massive paralleling for power or for capacity is possible. If the total discharge does not exceed 130 A or 5 kW, connecting any number of Evolion on the same bus, in theory, is acceptable.

  • Page 27: Thermal Characteristics In Cycling

    For frequent cycling application limiting the current on charge and discharge will also limit the maximum steady state temperature of the Evolion in cycling. A good rule of thumb is to not exceed 25 Amps of re-charge current per Evolion in applications where more than 2 cycles per day and less than 5 cycles per day are needed.

  • Page 28: Adding Modules To Existing Bus

    13.3 Adding modules to existing bus When adding an Evolion to an existing power bus, the maximum voltage difference for the modules to be added is 2 V from the bus set point. This maximum allowed voltage difference prevents the inrush current sharing between modules to exceed 44 A and thus avoid the charge regulated mode.

  • Page 29: Autonomy Sizing

    15.1 Autonomy sizing To determine the # of Evolion modules needed to provide a minimum autonomy, use the following equation along with the performance rate tables and external derating factors. See the chapter Discharge performance factors and the rate table and graphs in Appendix C...
  • Page 30 An example is given: The customer needs to backup a remote roadside cabinet (remote terminal) for 4 hours. The average yearly outside temperature is 29 ºC. The coldest temperature is 0 ºC. The load is 120 Amps. The performance should be guaranteed for 10 years.
  • Page 31 772518 Communication cable, inter module 773455 RJ45 Resistor cap 773456 Converter cable 774884 Busbar kit, 4x Evolion, 1 meter communication cable to application 780680 Cable POS, 1000 mm, black cable, red heat shrink Appendix B: Glossary Term Definition BMST Battery Management System Telecom...
  • Page 32 Appendix C: Performance rate tables Performances are based on the typical capacity C = 77 Ah Autonomy (hours) 42 V end voltage Amps 37.4 25.1 19.0 9.63 7.74 6.48 4.89 3.24 Watts 1810 1229 Avg V 48.5 48.9 49.2 50.4 50.4 50.4 50.7...
  • Page 33 – derating factor for less than 10ºC taking into account the heater load. Use either f or f , both should not be applied. 100% 2-hour rate 4-hour rate 8-hour rate Heater control always ON control always OFF - 40ºC 10ºC 15ºC 75ºC...
  • Page 34 – derating factor for cut-off voltage higher than 42 V. EODV 100% 43.2 V 44.4 V 45.6 V 46.8 V Autonomy (hours) – derating factor for aging. aging 100% 5 years 10 years 15 years 20 years Average environment temperature (ºC)
  • Page 35 Appendix E: Alarms and troubleshooting Use the Evolion Toolbox software to diagnose active alarms. See Evolion Toolbox Software Technical Manual for more details. Fault codes are indicated here n° Fault code is active (major alarm) with open electronic switch (mosfet); Evolion operates in safe mode.
  • Page 36 Fault code is active (major alarm) with open electronic switch (mosfet); Evolion operates in safe mode. n° Warning alarm is active with closed electronic switch; Evolion operates in normal mode. Generic Buffer Description Fault condition Possible cause and notes Recommended action guide n°...
  • Page 37 Fault code is active (major alarm) with open electronic switch (mosfet); Evolion operates in safe mode. n° Warning alarm is active with closed electronic switch; Evolion operates in normal mode. Generic Buffer Description Fault condition Possible cause and notes Recommended action guide n°...
  • Page 38 Fault code is active (major alarm) with open electronic switch (mosfet); Evolion operates in safe mode. n° Warning alarm is active with closed electronic switch; Evolion operates in normal mode. Generic Buffer Description Fault condition Possible cause and notes Recommended action guide n°...
  • Page 39 Fault code is active (major alarm) with open electronic switch (mosfet); Evolion operates in safe mode. n° Warning alarm is active with closed electronic switch; Evolion operates in normal mode. Generic Buffer Description Fault condition Possible cause and notes Recommended action guide n°...
  • Page 40 Fault code is active (major alarm) with open electronic switch (mosfet); Evolion operates in safe mode. n° Warning alarm is active with closed electronic switch; Evolion operates in normal mode. Generic Buffer Description Fault condition Possible cause and notes Recommended action guide n°...
  • Page 41 Fault code is active (major alarm) with open electronic switch (mosfet); Evolion operates in safe mode. n° Warning alarm is active with closed electronic switch; Evolion operates in normal mode. Generic Buffer Description Fault condition Possible cause and notes Recommended action guide n°...
  • Page 42 Saft has selected a recycling process for industrial lithium-ion cells with very high recycling efficiency. A list of our current collection points is available on our website. In other countries Saft assists users of its batteries in finding environmentally sound recycling solutions.

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