Summary of Contents for ABS ALLIANCE E Series
- Page 1 User’s Guide MODELS: ALLIANCE E-SERIES (E48-20) DOCUMENT NUMBER AND REVISION Doc # 0055 Version 1.0...
- Page 2 Alliance Intelligent Battery Series User’s Guide COPYRIGHT NOTICE Copyright © 2020 American Battery Solutions, Inc. All rights reserved. Document Notice The information contained in this manual is the property of American Battery Solutions, Inc. (“American Battery Solutions”) and is subject to change without notice. American Battery Solutions reserves the right to make changes in the design of its products or components as progress in engineering and manufacturing may warrant.
- Page 3 User’s Guide Trademarks ABS and the ABS logo are trademarks of American Battery Solutions, Inc. Alliance Intelligent Battery Series™ and its logo are trademarks of American Battery Solutions, Inc. All other trademarks used herein are the property of their respective owners.
- Page 4 American Battery Solutions, manufacturer of the world’s most trusted Lithium Ion batteries. The battery you purchased was engineered by ABS to deliver superior energy, run-time, durability, and reliability for use in a broad range of demanding applications. Our goal is to...
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Page 5: Table Of Contents
Alliance Intelligent Battery Series User’s Guide Contents Preface About this Guide ......................7 Audience........................7 Conventions .........................7 Danger, Warning, and Caution Notices ..............8 Typography ........................ 8 Support .........................8 Related Documents and Resources .................9 Introducing the Alliance Intelligent Battery Series™ Alliance Intelligent Battery Series™ Product Line ..........10 Regulatory Compliance Environmental Compliance .................. - Page 6 Alliance Intelligent Battery Series User’s Guide Battery Configuration ....................32 Integrated Battery Protection ................. 33 Transient Energy Limit..................... 33 Over-Current Protection ..................34 Over-Discharge Protection (Under-Voltage Protection) ........34 Smart Charger Support ................... 35 Over-Charge Protection (Over-Voltage Protection)..........36 Over-Temperature Protection ................36 Low Temperature Operation ..................
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Page 7: About This Guide
Solutions documentation: About This Guide This User’s Guide was created by ABS engineers and contains vital information regarding proper care and maintenance of your new battery. Please read through this User’s Guide carefully and completely before using your battery. It will help you achieve optimum performance and long life from your new investment. -
Page 8: Danger, Warning, And Caution Notices
Alliance Intelligent Battery Series User’s Guide Danger, Warning, and Caution Notices Typography In this manual: Blue text identifies cross references to other topics or external hyperlinks Support Please contact American Battery Solutions Customer Support at 248-462-6364 in North America, +1 248-462-6364 outside of North America, or e-mail service@americanbatterysolutions.com.com ©... -
Page 9: Related Documents And Resources
Alliance Intelligent Battery Series User’s Guide Related Documents & Resources • Link to International Civil Aviation Organization (ICAO) Technical Instructions: http://www.icao.int/safety/DangerousGoods/Pages/default.aspx • Link to International Air Transport Association (IATA) Dangerous Goods Regulations: http://www.iata.org/whatwedo/cargo/dgr/Pages/lithium-batteries.aspx • Link to International Maritime Dangerous Goods (IMDG) Code: http://www.imo.org/Publications/IMDGCode/Pages/Default.aspx •... -
Page 10: Introducing The Alliance Intelligent Battery Series
Alliance Intelligent Battery Series User’s Guide Introducing the Alliance Intelligent Battery Series™ Alliance Intelligent Battery Series™ Product Line American Battery Solutions’ Alliance Intelligent Battery Series™ product line is a family of lithium-ion batteries designed to provide exceptional energy, run-time, and cycle life in a variety of applications*. - Page 11 Alliance Intelligent Battery Series User’s Guide battery has integrated protection and balancing circuitry (see Figure 2) that safeguard the battery from over-current, over‐voltage, under‐voltage, short circuit, and over‐ temperature conditions. Figure 2: Alliance Intelligent Battery Series™ Battery Block Diagram © 2020 American Battery Solutions Inc. All rights reserved. The data herein is intended as a guide and does not reflect the specification range for any particular property of this product.
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Page 12: Regulatory Compliance
Alliance Intelligent Battery Series User’s Guide Regulatory Compliance All Alliance Intelligent Battery Series™ models are compliant with, or tested to, these standards: Table 1: Regulatory Standards for Alliance Products Standard Description UL 2271 Compliant Batteries for Use in Light Electric Vehicles IEC60529 Meets IP67 Environmental Enclosure rating. -
Page 13: Environmental Compliance
Alliance Intelligent Battery Series User’s Guide Environmental Compliance The battery is compliant with these environmental directives and regulations. • EU Directive 2011/65/EC on the Restriction of the use of certain Hazardous Substances (RoHS) in electrical and electronic equipment (recast) • EU Directive 2006/66/EC on batteries and accumulators and waste batteries and accumulators •... -
Page 14: Regulations Overview
Alliance Intelligent Battery Series User’s Guide Regulations Overview Rechargeable lithium-ion cells and batteries are considered Dangerous Goods. The regulations that govern their transport are based on the UN Recommendations on the Transport of Dangerous Goods Model Regulations. Transport of dangerous goods is regulated internationally by: •... -
Page 15: Following International And U.s. Dot Regulations
Alliance Intelligent Battery Series User’s Guide Following International and U.S. DOT Regulations Failure to comply with International and U.S. DOT regulations while transporting Class 9 Hazardous Materials (Dangerous Goods) may result in substantial civil and criminal penalties. The USDOT requires training for anyone who handles hazardous materials including individuals who ship or receive hazardous materials, prepare hazardous materials for transportation, mark and label containers, complete shipping documents, select packaging and load or unload hazardous materials. - Page 16 Alliance Intelligent Battery Series User’s Guide Table 3 shows the proper shipping names and UN numbers required for shipping lithium-ion batteries. Table 3: Proper Shipping Names and UN Numbers Proper Shipping Name Description Lithium ion batteries UN 3480 Lithium ion batteries packed with equipment UN 3481 Lithium ion batteries contained in equipment UN 3481...
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Page 17: Handling, Storage, And Installation
Alliance Intelligent Battery Series User’s Guide Handling, Storage, and Installation Safety and Handling The Alliance Intelligent Battery Series™ battery is abuse tolerant, however correct handling and system integration of the battery are still important to ensure safe operation. The advanced design of the Alliance Intelligent Battery Series is intended to provide protection against operation under many unsafe conditions such as over-voltage, under- voltage, over-temperature, and short-circuit. - Page 18 Alliance Intelligent Battery Series User’s Guide Table 4: Proper Handling and Usage Guidelines ALWAYS NEVER Always wear proper personal protective Never wear jewelry or other metal objects when equipment (eye protection and gloves) working on or around batteries Always use insulated tools when working Never place objects on top of batteries on batteries Always check connections for proper...
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Page 19: Mounting And Installation
Alliance Intelligent Battery Series User’s Guide Mounting and Installation Alliance Intelligent Battery Series™ batteries may be installed in the following orientations: • Terminals up-right • Terminals on the side Batteries need hold-downs or restraints to prevent the battery from moving, excessive shock and vibration. -
Page 20: Wiring Connections
Alliance Intelligent Battery Series User’s Guide Wiring Connections To connect Alliance Intelligent Battery Series™ batteries, use appropriately sized wire, cables, and lugs that are rated for the maximum current and temperature expected. See table 6 for Environmental operation conditions. The battery can accommodate a maximum inductance of 10 μH. For reference, 10 μH is equivalent to 6 meters (20 feet) of individual standalone cable. -
Page 21: Configuring Batteries In A Parallel Group (Up To 1S10P)
Alliance Intelligent Battery Series User’s Guide When wiring lugs: 1. Connect a wiring lug directly to the surface of each battery terminal. Do not place a washer between the terminal base and the lug. 2. Next, place a flat washer on top of the lug, followed by a split washer, and finally by the bolt or nut. -
Page 22: Series And Parallel Battery Configuration Warning And Notices
Alliance Intelligent Battery Series User’s Guide Series and Parallel Battery Configuration Warning and Notices Connecting Alliance Intelligent Battery Series Communication Cables The Alliance Intelligent Battery Series™ intelligent battery has a special 10-pin communication connector. American Battery Solutions can provide harnesses for connecting modules to industry standard D-sub 9 connectors or open wires for connecting to system or vehicle wire harnesses for industry standard CAN bus communications as shown in Figure 3. -
Page 23: Transportation And Storage
Alliance Intelligent Battery Series User’s Guide Figure 3: 9-Pin D-Sub Communication Cable Connector Pin-Out Descriptions Transportation and Storage When storing or transporting the Alliance Intelligent Battery Series™ batteries, American • Batteries can be stored in an environment with average temperatures between ‐40 Battery Solutions recommends the following: °C and +35 °C, between 5% and 95% relative humidity, noncondensing, and at altitudes up to 25,000 feet (7600 m). -
Page 24: Operating Environment
Alliance Intelligent Battery Series User’s Guide Operating Environment Alliance Intelligent Battery Series™ batteries are engineered to disconnect from the host system under a variety of conditions in order to avoid internal damage. When this occurs in equipment with Alliance batteries, all power will be lost. In certain types of equipment, an abrupt interruption of power can cause undesirable and unexpected equipment behavior, such as braking loss or sudden braking. -
Page 25: Alliance Intelligent Battery Series Specifications
Alliance Intelligent Battery Series User’s Guide Alliance Intelligent Battery Series Specifications Electrical and Environmental Specifications Table 5: Alliance Intelligent Battery Series Electrical Specifications Specification Description Maximum Continuous Discharge Current to 100% DOD at 25 °C Maximum Continuous Charge Current to 100% capacity at 25 °C Maximum Pulse Discharge Current 150A for 2sec... -
Page 26: Physical Specifications
373 x 233 x 99 mm (14.7 x 9.17 x 3.9 in) Weight (approximate) 10.2 kg (22.5 lbs.) Case Material ABS Plastic, UL 94 V0 Flame Rating Terminal Bolt Requirements Tin Plated Copper, M8 x 1.25mm torque up to 9Nm (79.7in-lbs) Maximum Terminal Temperature (before 90 °C... - Page 27 Alliance Intelligent Battery Series User’s Guide Figure 4: Alliance Intelligent Battery Series Mechanical Dimensions © 2020 American Battery Solutions Inc. All rights reserved. The data herein is intended as a guide and does not reflect the specification range for any particular property of this product.
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Page 28: Operation And System Design
Alliance Intelligent Battery Series User’s Guide Operation and System Design General Battery Optimization The Alliance Intelligent Battery Series™ battery technology incorporated an intelligent Battery Management System (BMS) which ensures safe Battery Operation. The BMS shall operate mainly in 2 Modes: Drive and Charge. Figure 5: Battery State Diagram Drive mode is initiated via CAN or IGN Low;... -
Page 29: Battery Management System (Bms) Initialization And Wakeup
Alliance Intelligent Battery Series User’s Guide Figure 6: Fault State Transition Diagram The BMS shall enter Fault Error Mode based on any of the Protection Features as mentioned in further sections. The BMS has escalating fault states for many of the failure conditions with (Warning, Moderate and Sever) with elevating effects to the condition. -
Page 30: Battery Management System (Bms) Modes Of Operation
Alliance Intelligent Battery Series User’s Guide b. IGN-Based Wakeup The Alliance Intelligent Battery Series™ can be woken by connecting the Ign Low (Pin 2 of the low voltage connector) to the negative terminal of the battery or connecting the Ign +12V to an external 12V source. (It is assumed that connection to the negative terminal of the battery is through chassis ground or the application wiring harness.) When either Ing pin is activated (Switching Ign Low to ground or applying 12V to Ign +12V) will enter Drive mode (assuming no... - Page 31 Alliance Intelligent Battery Series User’s Guide For CAN based systems, the states can be commanded through the HOST_stateRequest Signal in the HOST_batteryRequest Message (0x502). The Drive and Charge states allow current to flow in and out of the battery. The Standby and Standby Not Ready states indicate that the BMS is awake but not delivering power, either by the None command or because there is a fault in the system preventing the power to/from the battery.
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Page 32: Battery Configuration
Alliance Intelligent Battery Series User’s Guide Battery Configuration The Alliance Intelligent Battery Series™ can be configured to operate as a single module or with multiple modules in parallel if additional power or energy required. (Series configuration of the Alliance Intelligent Battery Series™ is not supported and will result in permanent damage to the BMS if configured as such). -
Page 33: Integrated Battery Protection
Alliance Intelligent Battery Series User’s Guide Table 10: Alliance Intelligent Battery Series™ Multi-Module Faults Event Condition Module Select Disagreement Inter-module pre-charge ID mismatch Module Connect Fault One or more permitted modules failed to pre-charge or join bus Module MIA One or more inter-module critical messages missing (see inter-module data section) Module Imbalance Difference in voltage too great to join bus... -
Page 34: Over-Current Protection
Alliance Intelligent Battery Series User’s Guide Over-Current Protection The Alliance Intelligent Battery Series™ calculates current limits based upon current direction (Discharge/Charge), State of Charge (SOC), temperature, current value and amount of time at the current value. Figure 10: BMS Current Control Limits The Alliance Intelligent Battery Series™... -
Page 35: Smart Charger Support
Alliance Intelligent Battery Series User’s Guide drop to 0 volts. Terminals will be allowed to reconnect once the voltage has increased above 2.78 volts for 20 seconds. Slight differences in the cells’ capacity lead to differences between the cell voltages, especially at low states of charge. -
Page 36: Over-Charge Protection (Over-Voltage Protection)
Alliance Intelligent Battery Series User’s Guide voltage measurement device. Over-Charge Protection (Over-Voltage Protection) Similar, but opposite to the case at low states of charge, the Alliance Intelligent Battery Series™ terminal voltage begins to rise rapidly at high states of charge. The Alliance Intelligent Battery Series™... - Page 37 Alliance Intelligent Battery Series User’s Guide Both charge and discharge functions increase battery temperatures. High rate battery usage causes the largest temperature increase. The Alliance Intelligent Battery Series™ over temperature protection (OTP) circuitry disconnects the terminals if the battery exceeds the temperature limits. During high rate battery usage, the user must ensure that ambient operating temperature combined with the charge or discharge rate does not exceed the operational temperature limits.
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Page 38: Low Temperature Operation
Alliance Intelligent Battery Series User’s Guide Low Temperature Operation At low temperatures, the maximum available discharge power decreases due to increased internal impedance at lower temperatures. 1. Under Temperature Warning – Under Temperature Warning sets a warning flag if any of the Battery cell Temperatures go below minimum operating temperature. This notifies the user the to take appropriate actions and use the battery efficiently without opening the FETs. -
Page 39: Constant Current (Cc), Float Voltage Chargers
Alliance Intelligent Battery Series User’s Guide Constant Current (CC), Float Voltage Chargers For Alliance Intelligent Battery Series™ batteries operating under normal conditions during a charge, a charger applies Constant Current (CC) until the terminal voltage reaches its End of Charge (EOC) voltage (maximum), as shown in Figure 11. -
Page 40: Charger Recommendation
Alliance Intelligent Battery Series User’s Guide Charger Recommendation Delta-Q IC-series CANOpen chargers are recommended for Alliance Intelligent Battery modules. Series™ Charge Limits and Temperatures At room temperature and above, the Alliance Intelligent Battery Series™ battery can accept full rated charge. As with all battery technologies, charge acceptance is limited at low and high temperatures. - Page 41 Alliance Intelligent Battery Series User’s Guide Figure 12: Connecting multiple modules in parallel to a charger When charging multiple batteries, maximum charge current should not exceed the number of modules multiplied by the single module current limit for the number of Alliance Intelligent Battery Series™...
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Page 42: Discharge Performance
Alliance Intelligent Battery Series User’s Guide Discharge Performance Compared to lead-acid batteries, the output voltage of the Alliance Intelligent Battery Series™ remains relatively constant across its capacity range at any given discharge rate. As the Alliance Intelligent Battery Series™ battery discharges, limited voltage drop translates into superior (I x V) power delivery capability. -
Page 43: Cycle Life
Alliance Intelligent Battery Series User’s Guide Alliance Intelligent Battery Series™ batteries are shipped at 30% SOC. Fully charging the Alliance Intelligent Battery Series™ at float voltage for 4-24 hours prior to first use will ensure optimal balance and maximize the first discharge delivered capacity. Cycle Life Cycle life is dependent upon many application-specific factors including operating temperature, charge/discharge rates, state of charge swing, and calendar time. -
Page 44: Can Network Configuration
Alliance Intelligent Battery Series User’s Guide built into the hardware layer, making for a robust network that can operate reliably in electrically noisy environments. The Alliance Intelligent Battery Series™ network interface is compatible with CAN-to-USB adapters that provide galvanic isolation only. The Vector CAN Case and PCAN have been evaluated by American Battery Solutions and are known to work. -
Page 45: Can Bus Settings
Alliance Intelligent Battery Series User’s Guide Figure 13: CAN Bus Interface CAN Bus Settings The default CAN bit rate is 500 kbit/s with the sample point set to 75% and a synchronization jump width of 2 bits. To support any other Baud rate, please contact American Battery Solutions technical support to give proper solutions. - Page 46 Alliance Intelligent Battery Series User’s Guide Table 13: Alliance Intelligent Battery Series™ messages and signals on the CAN interface SIGNAL NAME MESSAGE MESSAGE UNIT COMMENT BATT_USERMODE BATT_userInputs 0x100 0 - Request to be reduced Range... BATT_USERSOC BATT_userDisplay 0x101 State of Charge for the battery pack BATT_PACKFULLCAPACITY_AH BATT_packStatus 0x103...
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Page 47: Operational Protection Alarms And Settings
Alliance Intelligent Battery Series User’s Guide Operational Protection Alarms and Settings Table 14 lists the Alliance Intelligent Battery Series™ Operational Protection matrix covering warnings, alarms and hardware circuitry for voltage and temperature. Table 14: Alliance Intelligent Battery Series™ Operational Protection Settings Warning Set Moderate Set Severe Set... - Page 48 Alliance Intelligent Battery Series User’s Guide Table 15: Alliance Intelligent Battery Series™ Event Matrix Event ID Charge Drive Full Module Event Name Charge Drive Regen (Hex) Entry Entry Power Battery 0x1106 Brick Overvoltage Severe Battery 0x1105 Brick Overvoltage Moderate Battery 0x1104 Brick Overvoltage Warning Battery...
- Page 49 Alliance Intelligent Battery Series User’s Guide Table 15: Alliance Intelligent Battery Series™ Event Matrix cont. Event ID Charge Drive Full Module Event Name Charge Drive Regen (Hex) Entry Entry Power Platform 0x50C5 Abnormal Reset Reason Platform 0x5015 Flash App CRC Error Platform 0x5025 Flash Bootloader CRC Error...
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Page 50: Faq
Alliance Intelligent Battery Series User’s Guide For unused inputs (Ign Low, Ign 12V) it says that momentary application will turn on ignition, but also unused inputs should be N/C. Q: Does this imply that a momentary signal is needed? A: The batteries can be woken with 3 different methods, Wake on CAN, Wake on Ign- Wake on Ign +12V. - Page 51 Alliance Intelligent Battery Series User’s Guide Q: What is the timeout period? How frequent do CAN messages need to come? A: Message times are defined in the DBC file. Messages from the host are expected every 1000 ms and timeout currently is after 10 seconds. Q: If CAN is not used how does the keep alive work? A: By grounding the Ign- pin.
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Page 52: Troubleshooting
Alliance Intelligent Battery Series User’s Guide Troubleshooting Despite the high reliability of the Alliance Intelligent Battery Series™ batteries, you may encounter situations where the battery does not operate as expected. This chapter details potential issues with integrating the Alliance Intelligent Battery Series™... -
Page 53: Glossary
Alliance Intelligent Battery Series User’s Guide Glossary Ampere. Alternating Current. AC BUS A common connection line for AC elements, such as the inverter’s AC-side connection. AC Resistance With respect to a cell’s resistance, the passive resistance of a cell, not including the electrochemical and ionic resistances. - Page 54 Alliance Intelligent Battery Series User’s Guide Beginning of Life; the state of the product at the beginning of its commissioning. Controller Area Network: a communications protocol used for communication between battery modules, battery management systems, and customer application systems. Cell A single unit of electrical energy storage.
- Page 55 Alliance Intelligent Battery Series User’s Guide LVCO Low voltage Cut-off Module See Battery Module. Over Current Protection. Over Temperature Protection. Over Voltage Protection. Power. Process Data Object. Personal Protective Safety gear required when working in a potentially unsafe Equipment environment, including but not limited to high voltage equipment.