Check installation requirements....................47 5.1.1 Requirements for stability....................47 5.1.2 Requirements for protection against damage............47 5.1.3 Requirements for ease of operation and maintenance..........47 Install evoTractionBattery....................... 48 Connecting the evoTractionBattery....................49 5.3.1 Connect battery terminals and equipotential bonding........... 49 5.3.2 Connect charger........................50 5.3.3 Connect external components..................
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Controls and displays........................66 Read out system values........................66 LED indicators interpret........................67 Detect and fix errors.........................67 Maintenance..............................69 Maintain and service.........................69 Replace evoTractionBattery......................70 Power/signal cable replacement....................72 Accessories and spare parts......................72 Service, maintenance and support....................72 Disposal and recycling..........................73 TM_evoTractionBattery_1.4_en...
1 About this content About this content Below is important information about the content. Validity The content is valid for the following products: eTB48-50-025 F eTB48-100-05 F eTB48-200-10 F eTB48-300-15 F • • • • eTB96-50-05 F eTB96-100-10 F eTB96-150-15 F •...
1 About this content Additional information In the download area under eco-volta Download additional information can be found such as: Quick Guide (QG) • Warranty Terms and Conditions (WT) • Consumer Notes (CN) • How do you find the information? 1.
1 About this content Warnings and categories Warnings must be observed and are therefore specially marked. They contain information on potential damage or injuries so that accidents and damage can be prevented. DANGER Indicates an immediate threat which could lead to serious injuries or death. WARNING Indicates a potentially dangerous situation which could lead to serious injuries or death.
(already installed at the factory depending on the configuration). Work on live parts may only be carried out by specialized personnel. • Work on the evoTractionBattery may only be performed when it is switched off. • The user must not make any technical modifications to the evoTractionBattery.
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It must be ensured that no voltage is present before working on the electrical system. • Work on the electrical system must only be carried out by qualified personnel. • All connectors to the evoTractionBattery must be disconnected before starting work on the • electrical system. WARNING Electric shock due to improper wiring Contact with live parts can result in serious bodily injury or death.
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The evoTractionBattery may only be charged within the temperature range described in the • technical data. The evoTractionBattery must not be used at an altitude above 3500 meters above sea level. • The evoTractionBattery may only be charged with CAN bus-capable lithium-ion battery •...
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Possible damage to the evoTractionBattery due to deep discharge The storage of the evoTractionBattery under -10 °C and above 45 °C (max. 3 months) or • above 24 °C can lead to damage to the cell chemistry.
2 Basic safety information and warnings Fire protection measures WARNING Organic cell contents are flammable above 125 °C. In the event of overheating or fire, harmful gases will escape and the battery may explode. Harmful gases: Hydrogen fluoride • Carbon monoxide •...
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2 Basic safety information and warnings In case of clear smoke development or gas release: • Leave the room or the hazardous area immediately. ° Ensure that there is adequate ventilation. ° Fire watch Safety instruction Batteries can reignite even after a long time. Store the batteries under water after extinguishing them: in a sufficiently large water basin •...
2 Basic safety information and warnings Environmental protection The products of the ecovolta AG are designed with eco-design in mind to minimize their impact on the environment. The following features are considered standard in the design of the products: The products of the ecovolta AG are made of high quality materials to maximize the life of •...
• according to Directive 2013/53/EU Can the evoTractionBattery also be used for other applications? The evoTractionBattery may expressly be used for other applications only after written approval by the manufacturer. Which use is contrary to the intended use? The battery is considered to be used contrary to its intended purpose: The use of the battery for purposes other than those specified.
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11 Lithium-ion battery cells How does the evoTractionBattery work? The evoTractionBattery is equipped with lithium-ion battery cells that are charged and discharged via the built-in Battery Management System (BMS). The Battery Management System (BMS) is delivered from the factory with a standard configuration.
3 Product description Scope of delivery Standard scope of delivery The scope of delivery consists of: evoTractionBattery Original operating instructions NOTE This operating manual is an integral part of the product and is inseparable from the product If the product is passed onto other owners, then the operating manual also has to be passed The operating instructions can also be downloaded online.
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3 Product description Additionally required components INFORMATION Depending on regional legal regulation, it may be necessary to install additional suitable protective devices. Examples: Emergency stop for redundant protection of the high-voltage relay (highest priority) • Additional external safeguarding on both poles •...
3 Product description Technical data 3.3.1 Battery type overview There are the following types of batteries: eTB48-50-025 F eTB48-100-05 F eTB48-200-10 F eTB48-300-15 F 48 V 48 V 48 V 48 V 2.5 kWh 5.0 kWh 10.0 kWh 15.0 kWh For general technical data, see: "General technical data"...
3 Product description 3.3.2 General technical data The following technical data apply equally to all battery types: Environmental conditions Ambient temperature during charging -10 °C...+50 °C Ambient temperature during dis- -25 °C...+60 °C charge Ambient temperature during storage Up to 3 months: -10 °C...+45 °C From 3 months: -10...+24 °C Relative humidity max.
3 Product description Security Patented overcurrent protection per cell Equipotential bonding at the battery housing Certifications UN38.3, ECE-R 100, ECE-R 10, others in validation: ISO/ Conformity RoHS, in validation: CE 3.3.3 Battery type: eTB48-50-025 F Mechanical data Dimensions (L x W x H) 522 x 223 x 156 mm Total weight 23 kg...
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3 Product description Electrical data Pre-charging Up to nominal voltage Charging power 1191 W (continuous) at SoC 50 % *) Energy consumption offline/standby 0.015 µA Per cell Discharge depth DoD (project-specif- 72 % Life expectancy at 70% remaining ca- pacity (72% DoD or 3.2 V...4.0 V at Up to 2000 cycles +25°C) Insulation voltage...
3 Product description 3.3.4 Battery type: eTB48-100-05 F Mechanical data Dimensions (L x W x H) 522 x 223 x 213 mm Total weight 35 kg Color Housing: Yellow Lid: Anthracite (RAL 7011) Mounting type Upright on the stand or lying on a long side or end face Electrical data Nominal voltage...
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3 Product description Electrical data Life expectancy at 70% remaining ca- pacity (72% DoD or 3.2 V...4.0 V at Up to 2000 cycles +25°C) Insulation voltage >600 V Insulation resistance >1 MOhm Overvoltage category Recommended cable cross section 50 mm Battery terminal connections Amphenol SURLOK PLUS 8.0 mm Mating cycles...
3 Product description 3.3.5 Battery type: eTB48-200-10 F Mechanical data Dimensions (L x W x H) 522 x 223 x 322 mm Total weight 59 kg Color Housing: Yellow Lid: Anthracite (RAL 7011) Mounting type Upright on the stand or lying on a long side or end face Electrical data Nominal voltage...
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3 Product description Electrical data Life expectancy at 70% remaining ca- pacity (72% DoD or 3.2 V...4.0 V at Up to 2000 cycles +25°C) Insulation voltage >600 V Insulation resistance >1 MOhm Overvoltage category Recommended cable cross section 50 mm Battery terminal connections Amphenol SURLOK PLUS 8.0 mm Mating cycles...
3 Product description 3.3.6 Battery type: eTB48-300-15 F Mechanical data Dimensions (L x W x H) 522 x 223 x 437 mm Total weight 84 kg Color Housing: Yellow Lid: Anthracite (RAL 7011) Mounting type Upright on the stand or lying on a long side or end face Electrical data Nominal voltage...
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3 Product description Electrical data Life expectancy at 70% remaining ca- pacity (72% DoD or 3.2 V...4.0 V at Up to 2000 cycles +25°C) Insulation voltage >600 V Insulation resistance >1 MOhm Overvoltage category Recommended cable cross section 50 mm Battery terminal connections Amphenol SURLOK PLUS 8.0 mm Mating cycles...
3 Product description 3.3.7 Battery type: eTB96-50-05 F Mechanical data Dimensions (L x W x H) 522 x 223 x 213 mm Total weight 36 kg Color Housing: Yellow Lid: Anthracite (RAL 7011) Mounting type Upright on the stand or lying on a long side or end face Electrical data Nominal voltage...
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3 Product description Electrical data Life expectancy at 70% remaining ca- pacity (72% DoD or 3.2 V...4.0 V at Up to 2000 cycles +25°C) Insulation voltage >600 V Insulation resistance >1 MOhm Overvoltage category Recommended cable cross section 50 mm Battery terminal connections Amphenol SURLOK PLUS 8.0 mm Mating cycles...
3 Product description 3.3.8 Battery type: eTB96-100-10 F Mechanical data Dimensions (L x W x H) 522 x 223 x 322 mm Total weight 60 kg Color Housing: Yellow Lid: Anthracite (RAL 7011) Mounting type Upright on the stand or lying on a long side or end face Electrical data Nominal voltage...
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3 Product description Electrical data Life expectancy at 70% remaining ca- pacity (72% DoD or 3.2 V...4.0 V at Up to 2000 cycles +25°C) Insulation voltage >600 V Insulation resistance >1 MOhm Overvoltage category Recommended cable cross section 50 mm Battery terminal connections Amphenol SURLOK PLUS 8.0 mm Mating cycles...
3 Product description 3.3.9 Battery type: eTB96-150-15 F Mechanical data Dimensions (L x W x H) 522 x 223 x 437 mm Total weight 84 kg Color Housing: Yellow Lid: Anthracite (RAL 7011) Mounting type Upright on the stand or lying on a long side or end face Electrical data Nominal voltage...
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3 Product description Electrical data Discharge depth DoD (project-specif- 72 % Life expectancy at 70% remaining ca- pacity (72% DoD or 3.2 V...4.0 V at Up to 2000 cycles +25°C) Insulation voltage >600 V Insulation resistance >1 MOhm Overvoltage category Recommended cable cross section 50 mm Battery terminal connections...
3 Product description 3.3.10 Derating curve diagrams Curve diagrams of the behavior of the batteries can be found below. In each case during charging, discharging and recuperation as a function of cell voltage and temperature. Battery type: 48 V; 2.5 kWh Charge Current Derating [A] Charge Current Derating [A] vs.
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3 Product description Battery type: 48 V; 5.0 kWh Charge Current Derating [A] Charge Current Derating [A] vs. Temperature [°C] vs. Voltage [mV] Discharge Current Derating [A] Discharge Current Derating [A] vs. Temperature [°C] vs. Voltage [mV] Recuperation Current Derating [A] Recuperation Current Derating [A] vs.
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3 Product description Battery type: 48 V; 10.0 kWh Charge Current Derating [A] Charge Current Derating [A] vs. Temperature [°C] vs. Voltage [mV] Discharge Current Derating [A] Discharge Current Derating [A] vs. Temperature [°C] vs. Voltage [mV] Recuperation Current Derating [A] Recuperation Current Derating [A] vs.
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3 Product description Battery type: 48 V; 15.0 kWh Charge Current Derating [A] Charge Current Derating [A] vs. Temperature [°C] vs. Voltage [mV] Discharge Current Derating [A] Discharge Current Derating [A] vs. Temperature [°C] vs. Voltage [mV] Recuperation Current Derating [A] Recuperation Current Derating [A] vs.
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3 Product description Battery type: 96 V; 5.0 kWh Charge Current Derating [A] Charge Current Derating [A] vs. Temperature [°C] vs. Voltage [mV] Discharge Current Derating [A] Discharge Current Derating [A] vs. Temperature [°C] vs. Voltage [mV] Recuperation Current Derating [A] Recuperation Current Derating [A] vs.
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3 Product description Battery type: 96 V; 10.0 kWh Charge Current Derating [A] Charge Current Derating [A] vs. Temperature [°C] vs. Voltage [mV] Discharge Current Derating [A] Discharge Current Derating [A] vs. Temperature [°C] vs. Voltage [mV] Recuperation Current Derating [A] Recuperation Current Derating [A] vs.
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3 Product description Battery type: 96 V; 15.0 kWh Charge Current Derating [A] Charge Current Derating [A] vs. Temperature [°C] vs. Voltage [mV] Discharge Current Derating [A] Discharge Current Derating [A] vs. Temperature [°C] vs. Voltage [mV] Recuperation Current Derating [A] Recuperation Current Derating [A] vs.
3 Product description 3.3.11 PIN assignment of the CAN connections The pin assignment of the CAN connectors is as follows: CAN OUT External Signals CAN IN 12 V-ON (KL 15) (not used) 12 V-ON (KL 15) Unlocl Relais Common HV-Enable Display (max.
3 Product description 3.3.12 Lithium Ion Battery INFORMATION The following information is an excerpt and translation from LG's English product specifications. If you need more information please contact support@eco-volta.com. Nominal specification Type Specification Rated voltage Average: 3,7 V Standard charge Constant current: 0,5 C •...
3 Product description 3.3.13 Materials The components of the evoTractionBattery are made of the following materials: Component Material Spring steel Polyacetat Spacer Polyamide / PA 6.6 Polystyrene Spring steel Steel Fasteners Galvanized steel INOX Sheet metal components INOX, Aluminium Bolt...
3 Product description Marking Type plate Identify your battery by the type label: The type plate is located on the side of the battery housing. Interpret the pictograms on the type label: Type plate No. Meaning Manufacturer logo Warning of dangers due to battery leakage Warning of electrical voltage (>60 V DC) QR code (link to operating instructions)
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3 Product description Type plate Text Meaning Safe Usage Notes on safe use Operational Voltage Operating voltage Operational temperature Operating temperature Maximum Current Maximum output current Use only ecovolta authorized Only use chargers approved by charger ! ecovolta! Do not open ! Do not open the battery! Do not carry alone ! Do not carry battery alone!
4 Planning Planning Before installing an evoTractionBattery, the technical design of the system must be planned. Safety instruction This activity may be performed exclusively by specialized personnel (definition see Kapitel 1.2 "Target group"). Safety instruction The evoTractionBattery is preferably installed and operated horizontally on the stand.
Communication takes place via the CAN connection of the master battery, which automatically controls the slave batteries. Safety instruction The connection option of the evoTractionBattery depends on the order and can also only be used for this option! 4.2.1 Standalone battery This example shows the connection possibilities of a standalone battery: No.
4 Planning 4.2.2 Batteries in series connection This example shows the connection possibilities of several batteries in series connection: No. Meaning Charger Master battery S1 Slave battery 1 Slave battery x SB Signal distributor box External components: Ignition lock External battery button Display EMERGENCY STOP button Diagnostic device...
4 Planning 4.2.3 Batteries in parallel connection This example shows the connection possibilities of several batteries in parallel connection: No. Meaning Charger Master battery S1 Slave battery 1 Slave battery x SB Signal distributor box External components: Ignition lock External battery button Display EMERGENCY STOP button Diagnostic device...
5 Installation and commissioning Installation and commissioning The following is information on installing and commissioning the product. Check installation requirements The following are the requirements that are placed on the installation of the battery. 5.1.1 Requirements for stability Make sure that the following requirements are met: The standing surface for the battery is level and sufficiently load-bearing.
2. Lift the battery into the vehicle by the carrying handles and place it on the stand feet. Safety instruction The evoTractionBattery is preferably installed and operated horizontally on the stand. If the battery is to be installed lying on one side or standing on one end face: suitable devices should prevent the battery housing from being damaged due to specific areas of pressure.
5 Installation and commissioning Connecting the evoTractionBattery Safety instruction This activity may be performed exclusively by specialized personnel (definition see • Kapitel 1.2 "Target group"). Do not use multimeters for measurements. • Use only measuring instruments explicitly provided by the legislator: Voltage test instrument °...
5 Installation and commissioning Wire multiple batteries in parallel Wire multiple batteries serially Wire the batteries in parallel or series. See: "Connection options" 5.3.2 Connect charger To a standalone battery To a built-in battery No. Meaning Charger Battery SB Signal distributor box TM_evoTractionBattery_1.4_en...
5 Installation and commissioning 5.3.3 Connect external components All external components are connected via CAN bus to the signal distribution box, which is connected to the battery and to the charger. A project-specific signal distributor box is supplied for each application. The pictograms used in the following figures have the following meaning: Pictogram Meaning...
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5 Installation and commissioning Connect diagnostic device Connect the diagnostic device. (not occupied) white CAN_H brown CAN_GND green CAN_L Connect communication line to charging station (optional) Connect the communication line to the charging station. yellow green Connect HV_Enable (optional) Connect the HV_Enable signal: white HV_Enable (low active) brown...
5 Installation and commissioning 5.3.4 Wire system for charging the vehicle battery at a charging station The Battery Management System (BMS) supports PP/CP communication between the battery and the charging socket via the signal distribution box. This makes it possible to charge the battery at a charging station via a charging plug according to IEC 62196-2 (type 2).
5 Installation and commissioning Switch on and switch off the battery Depending on the firmware version of the battery, there are several ways to switch the battery on and off: On the battery pushbutton or on an external pushbutton • Per 12V_ON signal •...
5 Installation and commissioning 5.4.3 Switching the battery on and off at the battery button or at an external button In this version, the battery is switched on and off either at the built-in battery button or at an externally connected button. Switching operation Switch on battery: 1.
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5 Installation and commissioning Mode of operation with HV_ENABLE signal and external pushbutton In order for the battery to change to CHARGE mode, the battery must be in DRIVE mode and recognize the communication of one of the supported chargers via CAN. Alternatively, the battery can be set to CHARGE mode via the CAN bus.
5 Installation and commissioning 5.4.4 Switch battery on and off via 12V_ON signal In this version the battery is switched on and off by 12V_ON signal. This 12 V signal can come from the onboard 12 V starter battery via the ignition lock, for example. Switching operation Switch on battery: 1.
5 Installation and commissioning 5.4.5 Switch battery on and off via CAN-ENABLE signal In this version the battery is switched on with a combination of 12V_ON signal and CAN message. The 12V_ON signal wakes up the battery and the CAN message is used to enable the battery voltage. It is important that the BMS receives the CAN message with the ID 0x100 at least once per second in this version, so that it does not fall into an ERROR state.
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5 Installation and commissioning Functionality Safety instruction If the battery is completely discharged, it is imperative that the 12V ON and HV ENABLE signals are removed from the battery immediately and that the battery is promptly set to min. 30% SOC to be charged.
5 Installation and commissioning 5.4.6 Structure of CAN messages The battery has two CAN buses: CAN1: External bus for communication with the battery (baud rate = 500kbit/s) • CAN2: Internal bus for communication between batteries • The following CAN messages are available on CAN1: CAN ID RX/TX Name Description...
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5 Installation and commissioning CAN message 0x100 SCU_BMS_batEnable (RX) Length: 8 Byte Timing: <1000 ms Key Signals Name Byte Start bit Length [bit] Comments BMS_batHvEnable HV enable Signal, 0 = Idle, 1 = Drive-Mode BMS_batChEnable Charge enable, 0 = idle, 1 = charge mode, with active charge derating curves To ensure that the battery with the CAN firmware version works correctly and does not go into an ERROR state, the message with the CAN ID 0x100 must be sent on the CAN1 at least once per...
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5 Installation and commissioning CAN message 0x100 SCU_BMS_batEnable (RX) Length: 8 Byte Key Signals Name Byte Start bit Length [bit] Comments, batStatus1State *) Indicates in which mode the battery is (Idle, Drive, Charge, Error...). batStatus1InitMasters Indicates how many active batteries have been detected.
5 Installation and commissioning evoTractionBattery charging Safety instruction Only use chargers that use CAN communication to the BMS to charge the battery. NOTE No outgassing or other emissions are produced during charging. 5.5.1 Charging the vehicle battery at the charging station...
1. Disconnect all cable connections in reverse order. 5.5.4 Loading times The most efficient charging time can be expected at 0% to 80% residual capacity of the evoTractionBattery. A deeply discharged evoTractionBattery must not be charged because the TM_evoTractionBattery_1.4_en...
1 C Charging current corresponds to the charging current of the battery capacity. Example: A 50 Ah evoTractionBattery, which is equipped with 0,5 C is charged, charges with a charging current of 25 A. Putting the vehicle into operation INFORMATION Vehicle and customer-specific information can be found in your vehicle documentation.
6 Check system status and troubleshoot Check system status and troubleshoot The following is information on checking system health and troubleshooting. The prerequisite is a connected display. Controls and displays The display has the following controls and indicators: Figure Meaning LED (green): Load status LED (red): Warning LED (red): Discharge status...
6 Check system status and troubleshoot LED indicators interpret The LED indicators have the following meaning: Figure Meaning The battery is fully charged lights (SoC = 100 %). flashes The battery is charged. lights + beep At least 1 error has occurred. The battery charge is low.
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6 Check system status and troubleshoot Display Error cause Troubleshooting When the battery is discharged: Af- • ter waiting a few minutes, charge the battery. When the battery is fully charged: • Discharge the battery. Switch off the battery. • Error in HV relay (+) After waiting for 1 minute, start the •...
7 Maintenance Maintenance The following is information on the maintenance of the product. Maintain and service Maintenance plan Adhere to the following maintenance schedule: Maintenance interval Activity As needed see "Clean battery housing and installation location" At each cleaning, at least see "Check battery housing"...
° Check optical display Check the illumination of the battery button for function. • Replace evoTractionBattery INFORMATION The replacement battery must be configured according to the battery to be replaced. • Master/slave setting, node ID and baud rate of the replacement battery must match the •...
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7 Maintenance Procedure 1. Switch off the battery group. Safety instruction The main relay of the battery must be open for this operation, there must be no voltage at the power connector of the battery. 2. Disconnect and remove the power cable of the battery to be replaced. 3.
Accessories and spare parts Accessories and spare parts are obtained from: ecovolta AG Gersauerstrasse 71 +41 41 811 41 42 6440 Brunnen info@eco-volta.com Switzerland eco-volta.com Service, maintenance and support Service, maintenance and support are provided by ecovolta AG and their partners. TM_evoTractionBattery_1.4_en...
8 Disposal and recycling Disposal and recycling Do not dispose of the battery in household waste or other unsorted waste. Take the battery to the local recycling system for used batteries. If you have any questions about the materials and ingredients used, contact the manufacturer.
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