- Super B
Contents
1. External fuse 56 Batteries in series 56x13 2 750V 12 42VDC 5A CANOpen CANOpen Terminator Terminator CAN USB Terminator Monitoring Software Figure 16 Example 6 b MEN lithium batteries 5 Battery use 5 1 General information A Warning Keep the Li lon battery away from children 5 2 Charging Warning Never overcharge the Li lon battery this will permanently damage the battery Always use a charger which automatically halts the charging process when the battery is full Warning Stop the charging process if the battery gets too hot during charging gt 55 60 c Warning Never charge a battery with a charging current larger than 1C as this will damage the battery Caution Disconnect the charger from the mains and the battery if itis not used for a long time Caution To preserve the lifespan of the Li lon battery use a super B charger or a charger approved by super B The use of other chargers such as lead acid chargers will shorten the lifespan of the Li lon battery AGM GEL chargers may be used if the charge voltages of the different charge states don t exceed the charge voltage limits of the battery Connect the charger to the battery as described in paragrap2. SIE lithium batteries LITHIUM BATTERY 13 2V 160 Ah SB12V160E ZC 2 1kW LiFePO4 lithium batteries User Manual SB12V160E ZC Lithium Iron Phosphate battery Dear customer This manual contains all the information necessary to install use and maintain the super B SB12V160E ZC Lithium Iron Phosphate Battery We kindly ask of you to read this manual carefully before using the product In this manual the SB12V160E ZC battery will be referred to as the Li lon battery This manual is meant for the installer and the user of the Li lon battery Only qualified certified personnel may install and perform maintenance on the li lon battery Please consult the index at the start of this manual to locate information relevant you This is the original manual keep it on a safe location Copyright super B b v All rights reserved Licensed software products are owned by super B or its subsidiaries or suppliers and are protected by national copyright laws and international treaty provisions Super B products are covered by Dutch and foreign patents issued and pending Information in this publication supersedes that in all previously published material Specifications and price change privileges reserved Super B is a registered trademark of super B b v For more information or to order documents contact super B b v Diamantstraat 1e 7554 TA Hengelo Ov The Netherlands Tel 31 0 7482
3. 5 Fuse cover 6 Terminal 2x 95mm wire connection 7 Reset button 8 Fuse connections Lithium batteries to perform better 2 7 1 Cont 1 0 Connection 4 Pint OFF Pin2 ON Pins OFF Pin4 ON 2 7 2 2 1 0 connection 7 1 V 30 Volt 2 AN_SOC Analogue state of charge Pin3 Nc Not connected Pin4 Rc Relay common contact Pinb Rnc Relay normaly close contact Pin6 Rno Relay normaly open contact 7 GND Ground 2 8 Peripheral equipment 2 8 1 Obligatory In order for the Li lon battery to be used safely an approved external switch off device must be installed This should either be a relay or latching relay bi stable controlled by the battery s BMS or a relay or latching relay controlled by a remote switch CAN controlled see paragraph 4 4 Failure to install an external switch off device will void the warranty of the Li lon battery Use appropriate wire for the connection wires to ensure no overheating or unnecessary losses occur Consult the SAE J378 or ISO 10133 2012 standards to determine the appropriate wire properties Use appropriate fuses matching the wires and load lithium batteries 2 8 2 Optional The Li lon battery can be used in combination with a number of super B products Article name Article code SB GXL14B2B latching relay 9586 100 3105 0 SB LIR250 relay 9586 100 3106 0 SB V23130C2021A
4. Battery Monitoring Software Battery monitoring software offers the possibility to continuously monitor a number of battery properties through sensors within the Li lon battery It also enables one to download a complete recording of the battery s properties over time see paragraph 5 4 2 The Battery Monitoring software and the hardware needed to connect the battery to the computer is not included with the Li lon battery An overview of these products is given in paragraph Continuous Battery Monitoring The Battery monitoring software is able to continuously monitor and relay the following battery properties Battery serial number Battery voltage State of charge Charge Discharge current Battery status Alarms and Warnings Battery History Recording The complete battery history can be downloaded with the battery monitor software This recording can only be accessed by a reseller or super B for evaluation lithium batteries 6 Inspection cleaning and maintenance 6 1 General information Warning Never attempt to open or dismantle the battery The inside of the battery does not contain serviceable parts 1 Disconnect the Li lon battery from all loads and charging devices before performing cleaning and maintenance activities see paragraph 4 4 5 2 Remove the fuse or dummy fuse before cleaning and maintenance activities see paragraph 4 3 2 3 Place the included protective caps over
5. for transportation of lithium ion batteries which are assigned Class 9 Refer to relevant transportation documents Lithium and lithium ion cells and batteries are regulated in the U S in accordance with Part 49 of the Code of Federal Regulations 49 CFR Sections 105 180 of the U S Hazardous Materials Regulations Visit www iata org for the complete transport regulations and packing instructions for this product The relevant information for Lithium batteries can be found under Programs gt Cargo gt Dangerous goods HAZMAT 3 lithium batteries 9 Disposal and recycling 9 1 General information Always discharge the battery before disposal Use electrical tape or other approved covering over the battery connection points to prevent short circuits Battery recycling is encouraged Dispose of the battery in accordance with local state and federal laws and regulations Batteries may be returned to the manufacturer USA amp Canada Lithium Iron Phosphate batteries are subject to disposal and recycling regulations that vary by country and region Always check and follow your applicable regulations before disposing of any battery Contact Rechargeable Battery Recycling Corporation www rbrc org for U S A and Canada or your local battery recycling organization EC Waste must be disposed of in accordance with relevant EC Directives and national regional and local environmental control r
6. 11 Rev 4 b IEC 62281 Transportation IEC Compliance c SP 230 Special provision d SP 188 PI965 Part II IATA Packing instructions e Council Directive 2006 66 EC Environmental EU Compliance f Council Directive 2004 108 EC December 15 2004 on Electromagnetic Compatibility g IEC 62133 Safety IEC Compliance h IEC 61000 4 2 EMC Compliance i IEC 61960 ed2 0 Performance IEC Compliance M H Doornekamp CEO super Lithium batteries to perform better Appendix Ill Performance Graphs Depth of Discharge v s Cycle life Cycle Life at 23 C 80 Capacity Rating 1 000 000 00 100 000 00 C Charge C4 Discharge 10 000 00 Number of Cycles 1C Charge 2 Discharge 1 000 00 Low temperature discharge performance 25 deg 160A 0 deg C 160A 20 deg C 160A 20 40 60 Capacity lithium batteries 3 Load performance Discharge characteristics 25 deg C T 72 108 Capacity Ah Peukert component 160Ah Capacity Ah sr SB12V160E ZC GEL 160Ah 50 75 100 125 150 175 200 Discharge Current A Lithium batteries to perform better SUPER lithium batteries For more information or to order documents contact super B b v Diamantstraat 1e 7554 TA Hengelo Ov The Netherlands Tel 31 0 748200010 Fax 31 0 748200011 E mail info super b com www http www super
7. 275 20 kbit s 2500 m 137 5 m 687 5 m 10 kbit s 5000 m 275 1375 Table 2 CAN bus speed The default speed of the Can BUS is 250 kbit s A high speed bus requires termination at the two ends of the bus The CAN to USB converter can either be connected at one end of the bus with termination or in the middle of the bus with no termination termination should then be placed at the endnodes of the bus line Termination Resistors Use termination resistors at the end nodes to impede reflections on the line The value of this resistor should be 120 ohms More information on termination resistors can be found in CiA document 303_1 V1 8 0 section 5 Lithium batteries to perform better CAN bus power Due to the galvanic separation between the battery monitoring hardware and the battery an external power supply is needed for the CAN bus The CAN bus can be powered by either the SB MAS or the SB RSW If the SB MAS or the SB RSW cannot be used the CAN bus can be powered through Con 2 1 0 Connection 7 This situation may occur when a USB to CAN interface is directly connected to the battery Figure 6 1 Connect Pin 1 of Con2 to the terminal of the battery 2 Connect Pin 7 of Con2 to terminal of the battery Terminator V Battery Male SUPER aa 1 2 3 4 5 6 7 iid lololol eA MEN CAN USB m D attery Terminator
8. 5 2 1 Charging rate 5 22 Charging methods 5 23 Battery balancing 5 24 Battery equalization 5 25 Determining the battery s state of charge SoC 5 3 Battery use 5 3 1 Battery fault condition 5 4 Battery Monitoring Software 5 41 Continuous Battery Monitoring 5 42 Battery History Recording Inspection cleaning and maintenance 6 1 General information 6 2 Inspection 6 3 Cleaning 6 4 Maintenance Storage Transportation 8 0 General Disposal and recycling 9 1 General information 10 Troubleshooting 11 Warranty and liability 24 24 24 24 24 26 26 26 26 27 27 27 28 28 28 28 28 29 29 29 30 30 31 33 Lithium batteries to perform better 1 Introduction 1 1 Product description The SB12V160E ZC is a Lithium Iron Phosphate rechargeable battery Potential applications of this battery include off grid power supply marine power supply medium for renewable energy storage traction battery for vehicles The boundaries of its use as described in this manual should always be upheld The Li lon battery may not be used in medical or in aviation related applications The Li lon battery may not be used for any purposes other then described in this manual Using the battery for any other purposes will be considered improper use and will void the warranty of the product Super B b v cannot be held responsible for any damage caused by improper incorrect or unwise use of the product Read
9. and or product may occur when a procedure is not carried out as described N Caution A caution sign indicates problems may occur if a procedure is not carried out as described It may also serve as a reminder to the user 2 Product specifications 2 1 Product features Traction battery e Lithium Iron Phosphate 4 Most safe lithium technology Superior abuse tolerance Integrated BMS Glass fiber reinforced plastic GRFP Casing Aluminum PE sandwich side panels Terminals for 2 x 95mm2 wire connection per terminal e Integrated fuse 32V 500A continuous discharge 480A CANOpen interface for battery monitoring Battery monitoring History Storage Adaptive cell balancing Serial string equalization Serial string connection up to 1150V DC External BMS Relay latching bi stable e External BMS cut off switch CAN controlled 2 2 General product specifications Product name SB12V160E ZC Producer super B b v Battery type Lithium Iron Phosphate LiFeP04 5 to 10 years or 1000 2000 cycles at 1C charge discharge 8000 cycles at C4 charge discharge The lifespan value given above is an indication Battery lifespan dependents strongly on the applied charging and discharging loads For more information on the lifespan of the battery appendix 11 may be consulted Lithium batteries to perform better 2 3 Technical specifications Mass 28 3 Kg Ingress pr
10. and understand this manual completely before using the product Super B provides a CE declaration of conformity appendix 1 and a Certificate of Compliance appendix 2 for the product In accordance with CE guidelines a design and manufacturing schedule is available A Material Safety Data Sheet is also available The SB12V160E ZC complies with the following council directives e 2006 66 EC on Environmental EU Compliance 2004 108 EC December 15 2004 on Electromagnetic Compatibility The SB12V160E ZC complies with the following standards EC 61000 4 2 EMC Compliance EC 62133 Safety IEC Compliance EC 61960 ed2 0 Performance IEC Compliance EC 62281 Transportation IEC Compliance During the use of the product user safety should always be ensured so installers users service personnel and third parties can safely use the product The user must always have access to this manual keep it in a safe accessible location 1 2 Glossary of Terminology The products maximum lifespan achieved by adhering to the guidelines presented in this manual A period of use from fully charged to fully discharged and fully recharged again Endurance Life cycle Charge cycle RSW Remote switch BMS Battery management system SoC State of charge b MEN lithium batteries 1 3 Used symbols The following icons will be used throughout the manual A Warning A warning indicates severe damage to the user
11. appropriate installation instructions Connecting a latching relay to the battery 1 When using latching relay connect it to Con 1 1 0 Connection 4 as displayed in Figure 3 The internal driver controls both high and low side The output of Con 1 can be found in Table 1 v i Rae ees Te 1 Latching relay i Load 1 Battery terminal Charger Load Battery terminal H d 132N 250A N N LS REN x DC Charger SUPER Teh bates ra OLOLO O 2 3 4 GND Figure 3 Connect a latching relay as BMS switch off device Con 1 output 12V DC Continuous 100ms pulse 15A Table 1 Lithium batteries to perform better Connecting a normal relay as BMS switch off device A Warning Always connect the relay between the or terminal of the battery and the load 1 When using a normal relay connect it to Con 2 1 0 Connection 7 Pin 4 Rc and Pin 5 Rnc as displayed in Figure 4 Pin4 V max 250 VDC A max 5A Y Battery Rc Rnc Rno 1 2 3 4 5 6 Relay p tueri Fuse 5A 182 250A Charger Load Outside Battery x DC carer reste as Battery or Terminal EL voc GND GN
12. b com LI ION
13. current charge using an AGM GEL battery charger algorithm see Figure 18 Super B recommends using this charging method since it aids in balancing the battery prolonging the lifespan of the battery This charging algorithm is also used for AGM GEL batteries Setthe charge current and end of charge voltage to the values described in paragraph 5 2 1 Set the charger to go to float mode 13 7V 13 9V when the charge current drops below 3 of the recommended charge current 3 of 160A 4 8A Stage 1 Stage 2 Stage 3 w Constant current charge Topping charge Float charge UV A Charge current C3 T Minutes Figure 18 Constant voltage Constant current charge with AGM GEL battery charger algorithm lithium batteries 5 2 3 Battery balancing The Li lon battery is automatically balanced when the charger goes to float mode AGM GEL battery charger algorithm and no current is drawn from the battery see paragraph 5 2 2 5 2 4 Battery equalization During the batteries lifespan the cells within the battery may be unbalanced due to high discharge currents and short float charge periods This may result in a loss of capacity and overcharged cells Cells may be equalized by means of the following procedure 1 Apply a constant voltage of 14 2 and a current of lt 2A to manually equalize the Li lon battery 5 2 5 Determining the battery s state of charge SoC 1 Conne
14. 00010 Fax 31 0 748200011 E mail info super b com www http www super b com Lithium batteries to perform better Table of content 1 Introduction 5 T Product description 5 1 2 Glossary of Terminology 5 13 Used symbols 6 2 Product specifications 6 2 1 Product features 6 2 General product specifications 6 2 3 Technical specifications 7 2 3 1 Battery designation 7 2 3 3 Electrical properties 7 2 3 3 Dimensions 8 24 Environmental conditions 8 2 5 Required tools 9 2 6 Components 9 2 6 1 List of components 9 2 7 Connections indicators and battery controls 10 271 Cont 1 0 Connection 4 11 27 2 Con2 1 0 connection 7 11 2 8 Peripheral equipment 11 2 8 1 Obligatory 11 2 8 2 Optional 12 3 Safety guidelines and measures 12 3 1 General 12 3 2 Installation 13 3 3 Use 13 3 4 Disposal 13 3 5 Safety symbols and markings on product 13 4 Installation 14 4 1 General information 14 4 2 Unpacking 14 4 3 Preparing the battery for use 14 43 1 Placement of the battery 14 4 3 2 Placement and removal of a fuse 15 4 4 Installing the battery in an electrical circuit 16 44 1 Installing a BMS Switch off device 16 44 2 Connecting CANOpen interface 17 4 4 3 Connecting the battery to the load 19 4 4 4 Connecting a charger to the battery 21 4 4 5 Disconnecting a battery 21 4 4 6 More configuration options 22 9 SA lithium batteries Battery use 5 1 General information 5 2 Charging
15. 412 TE latching relay 9586 100 3108 0 SB MIC C TERMINATOR RESISTOR FEMALE STD WH 9586 100 4001 0 SB MIC C TERMINATOR RESISTOR MALE STD WH 9586 100 4002 0 SB CAN Patchcord 0 6m 9586 100 3001 0 SB CAN Patchcord 1m 9586 100 3002 0 SB CAN Patchcord 2m 9586 100 3003 0 SB CAN Patchcord 5m 9586 100 3004 0 SB CAN Patchcord 10m 9586 100 3005 0 SB CAN splitter 9586 100 3006 0 SB RSW1 9586 100 3007 0 SB MAS1 9586 100 3008 0 SB USB to Can 9586 100 3201 0 SB Monitor Software 9586 100 3201 0 SB AP 9586 100 3203 0 SB USB to CAN SB Monitor Software SB API total package Mounting bracket ZC casing 9586 300 0009 0 3 Safety guidelines and measures 3 1 General Warning Keep the battery away from fire excessive heat water dust and contamination A Corrosive Do not touch the battery s electrolyte after leakage If contact occurs flush with lukewarm water and seek medical assistance immediately A Warning Do not disassemble crush or puncture the battery Lithium batteries to perform better A Warning Keep the Li lon battery away from children A Warning Never touch the battery contacts or allow conductive objects to touch the contacts 3 2 Installation A Warning Never use the Li lon battery without a properly installed BMS switch off device controlled by either the Li lon battery or a remote switch SB RSW Use 3 3 A Warning Do not overcharge the Li lon battery A Warning Never short circuit the battery 3 4 Disposal Dispose
16. D GND GND Figure 4 Connect a normal relay as BMS switch off device 442 Connecting CANOpen interface To use the battery monitoring software the CAN bus of the Li lon battery CON 3 needs to be connected to the computer on which the monitoring software is installed More information on the CANOpen bus can be found at the CiA website www can cia org The required documentation can be found in the following CiA documents or in a future version of these documents e CiA 301 e CiA 303_1 V1 8 0 Sections 5 AC and DC parameters and 7 2 5 pin micro style connector CAN Bus network topology The CAN Bus must be used in a bus network topology see Figure 5 and Figure 6 Do not use a ring or a star topology The CAN specifications restrict the Bus length Bus speed Displayed in Table 2 is an overview of these restrictions susan lithium batteries Load External fuse 12 42VDC 5A Number of batteries in series Terminator sues pics D DC Charger SEM CANOpen CANOpen Terminator Terminator Max 1 5 Meter CAN USB J 3 GND Terminator Monitoring Software GND Figure 5 CAN Bus network topology Max stub Accumulated stub Bit rate Bus length L length S jm 1 Mbit s 25m 1 5m 7 5m 800 kbit s 50m 2 5m 12 5 500 kbit s 100 m 55m 27 5 250 kbit s 250 m 11m 55m 125 kbit s 500 m 22m 110m 50 kbit s 1000 m 55m
17. Monitoring Software Female Figure 6 Use Con2 to power the CAN bus 4 4 3 Connecting the battery to the load A Warning Ensure you have completed all the previous steps described in chapter 4 before connecting the battery to the load 1 Slide the terminal covers over the connection wires 2 Connect the terminal of the battery to the or A2 terminal of the relay Figure 7 1 3 Connect the load or charger to the or A1 terminal of the relay 4 Connectthe terminal of the battery Do not connectthe terminal first as this may lead to short circuits Figure 7 2 5 Ensure both contacts are tightened to 20 Nm 6 Place the terminal covers over the terminals Figure 8 lithium batteries Load Charger Latching Relay Load Charger Latching Relay Figure 8 Securing the terminal covers Bi stable Relay Battery terminal al oa 132V 250A SUPER GND GND Figure 9 Connecting the battery to the load Lithium batteries to perform better 4 4 4 Connecting a charger to the battery A Warning Ensure you have completed all the previous steps described in chapter 4 before connecting the battery to the charger 1 Connectthe charger behind the BMS switch off device as displayed in Figure 10 2 Disconnect the charger from the mains and the battery if it is not used for a long time Bi stable Relay Loa
18. OC Lithium lon Battery 13 2V 160Ah 2122Wh Energy TractionBattery The undersigned hereby declares on behalf of super B b v Hengelo the Netherlands that the above referenced product to which this declaration relates is in conformity with the provisions of Council Directive 2006 66 EC Environmental EU Compliance Council Directive 2004 108 EC December 15 2004 on Electromagnetic Compatibility European standards used EC 61000 4 2 EMC Compliance EC 62133 Safety IEC Compliance EC 61960 ed2 0 Performance IEC Compliance e IEC 62281 Transportation IEC Compliance The Technical Construction File required by this Directive is maintained at the corporate headquarters of super B b v Diamantstraat 1e 7554TA Hengelo the Netherlands M H Doornekamp CEO gt a 3 lithium batteries Appendix Il Certificate of Compliance super B b v Diamantstraat 1e 7554 TA Hengelo the Netherlands 31 0 74 8200010 www super b com November 7 2012 Certificate of Compliance Product Number Name Description SB12V160E OC Lithium lon Battery 13 2V 160Ah 2122Wh Energy TractionBattery The undersigned on behalf of super B does hereby certify that the product listed above is compliant to a The testing requirements for Lithium Batteries in Section 38 3 Part IIl of the UN Recommendations on the TRANSPORT OF DANGEROUS GOODS Manual of Tests and Criteria Fourth revised edition ST SG AC 10
19. ct Pin1 of 2 to the battery s pole 2 Connect Pin 7 of Con2 to ground 3 Determine the voltage at Pin 2 of CON2 see Figure 19 The analog SoC output ranges from 0 to 10 volt in which OV corresponds with 0 SoC and 10V corresponds with 10096 SoC The SoC is an indication Charging currents smaller then 100mA are not used in the SoC calculation 4 Take the battery through a complete charge cycle if the SoC indication does not provide an accurate representation of the SoC This will recalibrate the SoC GND GND Figure 19 Determining the batteries SoC Battery use Warning Do not short circuit the battery this may lead to battery damage explosion or fire Warning Never touch the terminals of the battery Warning Always use a BMS switch off device when connecting the battery to a load Warning Always remain within the limits indicated in paragraph 2 3 2 during the use of the Li lon battery PEEP Lithium batteries to perform better 534 5 4 0 4 1 54 Battery fault condition During battery use the external BMS switch off device may be triggered disconnecting the battery from all loads and the charger This shut off is the result of a fault condition To identify and resolve this fault condition chapter 10 may be consulted The Battery Monitoring software may also be used to identify a fault condition see paragraph 5 4
20. d Battery terminal 13 2V Co DC Charger SUPER lithium batteries GND GND Figure 10 Connecting the charger 4 4 5 Disconnecting a battery 1 Turn off any device or charger the battery is connected to 2 Turn off the external BMS latching relay or external BMS cut off switch 3 Disconnect the negative wire from the terminal of the battery 4 Disconnect the positive wire from the terminal of the battery lithium batteries b MEN 446 configuration options Other configurations to connect the battery are also possible see Figure 11 Figure 16 Bi stable Relay Load Battery terminal 13 21 500A 1 13 2V 500A Fuse 5A Bi stable Relay Figure 11 Example 1 Bi stable Relay Bi stablo Relay Load 28441250A Figure 13 Example 3 Figure 14 Example 4 1 External Fuse 500A 6 Batteries in series 6x13 2 79 2V Fuse 5A Figure 15 Example 5 Lithium batteries to perform better External fuse 56 Batteries in series 56x13 2 750V 12 42VDC 5A d Terminator CANOpen CANOpen Terminator Terminator 8 Strings in parallel
21. e wire from the pole of the battery see paragraph 4 4 for the details Disconnect the positive wire from the pole of the battery Unscrew the fuse cap using the fuse TORX key Unscrew the fuse contacts using the M13 wrench Press the reset button for 5 seconds Place the new fuse between the contacts place washers and spring washers and tighten the fuse contact points to 13 Nm 9 Fasten the fuse cap 10 Proceed to the next paragraph to read the instructions on installing the battery in an electrical circuit 9 54 2 XV NS Figure 2 Install a fuse lithium batteries 4 4 Installing the battery in an electrical circuit A Warning Never use the Li lon battery without a properly installed BMS switch off device relay or latching relay controlled by either the Li lon battery or a remote switch SB RSW A Warning Install the appropriate fuse before connecting the battery to other devices see paragraph 4 3 2 Use an appropriate external fuse if a dummy fuse is used 4 4 1 Installing a BMS Switch off device An external BMS switch off device can be either installed beween the or terminal of the battery and the load This BMS switch off device can be controlled in one of two ways Connect a latching relay or a normal relay to the battery s internal driver e Connect a latching relay or a normal relay to a remote switch SB RSW If applicable consult the manual of the SB RSW for the
22. ed in this manual Exposing the battery to conditions outside the specified boundaries may lead to serious damage to the product and or the user Lithium batteries to perform better Use the battery in a dry clean dust free well ventilated space Do not expose the battery to fire or water or solvents Operating temperature range Charge Operating temperature range Discharge Storage temperature range Relative humidity Placement angle continuously Maximum placement angle lt 48 hours Vibrations and shocks Required tools e M13 Hexagon socket wrench Fuse TORX key 2 6 25 1 Soe Components List of components 1 super B SB12V160E ZC Battery 4x M8 Bolt 6x M8 Spring washer 6x M8 Plain washer 2x M8 Nut 2x Mega Fuse 32V 500A 0 C to 45 C 20 C to 60 C 20 C to 60 C Between 5 and 85 non condensing lt 45 degrees 90 degrees As described in UN38 3 and IEC 6228 7 1x Dummy Fuse 8 1x Phoenix plug 4 9 1x Phoenix plug 7 10 2x Terminal cover Red 11 2x Terminal cover Black lithium batteries 2 7 Connections indicators and battery controls 1234567 1 Con 1 1 0 Connection 4 Phoenix FRONT MC 1 5 4 STF 3 81 1850877 2 2 1 0 Connection 7 Phoenix FRONT MC 1 5 7 STF 3 81 1850903 3 Con 3 CANOpen 5 pin micro style connector 4 Terminal 2x 95mm wire connection
23. egulations For disposal within the EC the appropriate code according to the European Waste Catalogue EWC should be used Other Many countries prohibit the disposal of waste electronic equipment in standard waste receptacles Lithium batteries to perform better 10 Troubleshooting Problem Possible reason Solution Connect the Monitor Software to the battery to verify the status of the battery If the battery status balancing required is active follow the procedures described in paragraphs 5 2 3 and 5 24 to balance the cells The cells within the battery are not properly balanced causing them to discharge at different The capacity of battery has decreased rates within the battery If no difference is found the lost capacity is due to battery aging This process cannot be reversed The battery does not provide a charge The fuse of the battery is not Install the fuse follow the procedures the battery installed described in paragraph 4 3 2 cannot be charged Disconnect all loads and chargers check and correct for short circuits The fuse in the battery is broken defects Then replace the fuse follow the procedures described in paragraph 4 3 2 The reset button was not pressed foro seconds Press the reset button for 5 seconds of the fuse or after a fault condition Batteries connected in series may Check the series for defective fail to charge if a defective batter
24. h 4 4 2 Charge the battery whenever the voltage of the battery drops below 10 V or if the state of charge drops below 20 to preserve the lifespan of the battery P PP PP 5 2 1 Charging rate Lithium Iron Phosphate batteries can be charged much faster then traditional lead acid batteries Displayed in Table 3 are the charge times for the Li lon battery at different charge currents Always use the indicated charge current and end of charge voltage during charging Consult paragraph 5 2 2 for the appropriate charging methods Time Charge current End of charge voltage Maximum 1 hour 1C 160A 15V DC Endurance lifecycle hours C3 52 8 14 6V DC Table 3 Charging rates at different charge currents 5 2 2 Charging methods Two charging methods may be used to charge the Li lon battery Constant voltage constant current charge see Figure 17 1 Setthe charge current and end of charge voltage to the values described in paragraph 5 2 1 2 Setthe charger to terminate charging when the charge current drops below 396 of the recommended charge current 396 of 160A 4 8A Lithium batteries to perform better v Stage 1 Stage 2 Constant current charge Topping charge 14 6 HA Charge current C3 Terminate Charge 1 when current lt 3 of recommended charge current 140 160 180 200 220 240 T Minutes Figure 17 Constant voltage Constant current charge Constant voltage constant
25. harger and all loads The battery has overheated and wait for the battery to cool down causing the battery management Then press the reset button or at system to trigger the external least b seconds to resolve the fault switch off device The BMS is condition The reset button can be now in fault condition found in the fuse compartment see paragraph 2 7 The Battery Management System has detected an error and 15 trying to trigger an external switch off device to disconnect from the Immediately disconnect the battery A ticking sound from the load and install a switch can be heard The BMS Uses un off device see paragraph 4 4 1 internal relay to do so However no external switch off device is connected to the BMS causing the internal relay to keep firing from within the battery Then press the reset button for at least 5 seconds to resolve the fault condition Lithium batteries to perform better 11 Warranty and liability 11 1 Upon delivery the customer is obliged to immediately verify whether the products have been damaged during transport If its not the customer must notify Super B of such transport damage as soon as possible in any event no later than within three 3 days of delivery by means of an accurate written statement stating the damage and where possible a photograph 11 2 If the customer demonstrates that the products do not conform to the agreement Super B has the opt
26. ion to repair and or replace the relevant products by new products when returned and or to refund the invoice value exclusive of any dispatch costs 11 3 If the customer is a private individual not acting for or on behalf of any company or business the customer has the right to return the product to Super B within seven 7 days of delivery In this event goods returned are only accepted if the product and its original packaging are free of damage while the dispatch costs for returning the goods shall be at the customer s expense 11 4 Super B shall use its best endeavors to manufacture reliable and safe products and to deliver these to the customer 11 5 Super B grants a three year limited warranty for manufacturing faults Manufacturing faults do not include damage caused as a result of a general tear and wear b short circuit c overcharging d deep discharging e a wrongful connection to engines and other devices f the absence of an approved and properly installed external BMS relay or other switch off device g any other wrongful use contrary to the user instruction and h any use contrary to the product specifications of that product 11 6 Any liability to the customer in any case ends if the customer fails to notify Super B of the existence of the defect within three 3 days of having discovered the defect in writing in order to enable Super B to investigate this 11 7 Any liability of Super B for damage suffered by
27. of the battery in accordance with local state and federal laws and regulations Batteries may be returned to the manufacturer Do not mix with other industrial waste LI ION 3 5 Safety symbols and markings on product A number of safety symbols and markings can be found on the product These markings are displayed below Never remove these markings Description Keep the Li lon battery upright Never tilt the battery more then 90 degrees Dispose ofthe Li lon battery in accordance with local state and federal laws and regulations Batteries may be returned to the manufacturer Do not mix with other industrial waste 151 LI ION This product or sections of this product can be recycled ve b 3 lithium batteries 4 Installation 4 1 General information Warning Do not disassemble crush or puncture the Li lon battery Warning Never install or use a damaged battery gt gt When connecting several batteries in series or parallel always use batteries of the same brand type age capacity and state of charge The Li lon battery is one on one replaceable with AGM GEL lead acid batteries 4 2 Unpacking Check the battery for damage after unpacking If the battery is damaged contact your reseller or super B Do not install or use the battery if it is damaged 4 3 Preparing the battery for use 4 3 1 Placement of the battery Before it is used the Li lon battery must be positi
28. oned in such a way it will not move around in its compartment during use If necessary the Li lon battery may be fixed in place by means super B mounting brackets The brackets can be screwed in place by means of bolts or screws See Figure 1 Figure 1 Installing the Li lon battery using the super B mounting brackets Lithium batteries to perform better 4 3 2 Placement and removal of a fuse Before the Li lon battery can be used either an internal fuse or a dummy fuse needs to be installed into it Two 32V 500A Mega fuses and one dummy fuse are supplied with the product Other fuses may only be used in the product when they are approved by super B for this application Use an internal Mega fuse if a single battery is installed if two batteries are installed in series or if a number of batteries are installed parallel to one another The discharge current may not exceeds 500 A and the maximum voltage may not exceed 32V see paragraph 4 4 Use a dummy fuse if three or more batteries are placed in series if maximum discharge current exceeds 500 A or if the maximum voltage exceeds 32V Warning Always use an external fuse with the appropriate value when a dummy fuse is used P Use the following steps to place a Mega Fuse or a dummy fuse in the battery Figure 2 Turn off any device or charger the battery is connected to Turn off the external BMS latching relay or external BMS cut off switch Disconnect the negativ
29. otection rating IP53 2 3 1 Battery designation Battery designation 41 227 415 315 2 3 2 Electrical properties Nominal voltage 13 2V DC Charge method CCCV End of charge voltage 15V DC End of charge voltage for endurance cycle life 14 6V DC Charge current 160A 1C Charge current for endurance cycle life 52 8A C 3 End of discharge voltage 8V DC End of discharge voltage for endurance cycle life 10V DC Maximum serial string connection voltage 1150V DC Discharge current 480A 3C Discharge current for endurance cycle life 52 8A C 3 Discharge pulse current 10 seconds external fuse 1280A 8C Discharge pulse current 60 second external fuse 800A 5C Discharge performance at 20 C rated capacity 160Ah 2112Wh Discharge performance at 20 C capacity 104Ah 1372 8Wh High rate discharge performance at 20 C capacity 144Ah 1841 4Wh Short circuit protection fuse 500A Self discharge 10 per year More information on the battery s discharge performance and capacity may be found in Appendix III SAE lithium batteries 2 3 3 Dimensions Height H 313 00 314 00 mm Width W 413 50 414 50 mm Thickness T 225 00 226 00 mm i SS Cs L d 413 5 414 5 2 4 Environmental conditions A Warning The Li lon Battery may only be used in conditions specifi
30. serve the battery s capacity Lithium batteries to perform better 7 Storage Follow the storage instructions in this manual to optimize the lifespan of the battery during storage If these instructions are not followed and the Li lon battery has no charge remaining when it is checked consider it to be damaged Do not attempt to recharge or use it Replace it with a new battery Remove the fuse from the battery during storage See paragraph 4 3 2 Disconnect the Li lon battery from all loads and if present the charging device Place the terminal covers over the battery s terminals during storage Store the battery in a cool and well ventilated space Avoid exposure of the battery to sunlight and or UV radiation Charge or discharge the battery to 5096 of its capacity before storage Charge the battery to approximately 5096 of its capacity at least once every 2 years SS Pe 8 Transportation 8 0 General Always check all applicable local national and international regulations before transporting a Lithium Iron Phosphate battery Transporting an end of life damaged or recalled battery may in certain cases be specifically limited or prohibited The transport of the Li lon battery falls under hazard class UN3480 class 9 For transport over water air and land the battery falls within packaging group PI965 Section Use Class 9 Miscellaneous Dangerous Goods and UN Identification labels 4 Ny
31. the customer is in any case limited to the invoice amount of the relevant products Super B can never be held liable for consequential damage or losses of profits unless such damage has been caused by gross negligence or willful misconduct of Super B 11 8 To the extent that a court determines that the limitation of liability as meant in clause 11 7 cannot be invoked against a particular claim for damages by the customer Super B s liability lithium batteries b MEN for loss of property damage to property and bodily injury including death caused by the application of those particular Super B products shall in any event be limited to the amount actually paid out by Super B s insurance company to Super B in accordance with the insurance cover of that insurance policy for that particular type of damage Super B has taken out insurance against certain risks namely for the application of Super B products in land vehicles and in aviation respectively each as described in the respective insurance policies These policies contain a usual limitation of insurance payment to be paid out to Super B if and to the extent that the event is a covered event Lithium batteries to perform better Appendix l EC Declaration of conformity super B b v Diamantstraat 1e 7554 TA Hengelo the Netherlands 31 0 74 8200010 www super b com November 7 2012 EC Declaration of Conformity Product Number Name Description SB12V160E
32. the terminals before cleaning and maintenance activities to avoid the risk of contacting the terminals 6 2 Inspection 1 Inspect for loose and or damaged wiring and contacts cracks deformations leakage or damage of any other kind If damage to the battery is found it must be replaced Do not attempt to charge or use a damaged battery Do not touch the liquid from a ruptured battery 2 Observe and note the run time that a new fully charged battery provides for powering your product Use this new battery run time as a basis to compare run times for older batteries The run time of the Li lon battery will vary depending on the products configuration and the application it is used for 3 Routinely check the battery s charge status Lithium Iron Phosphate batteries continue to slowly self discharge 10 per year when not in use or while in storage 4 Carefully monitor batteries that are approaching the end of their estimated life 5 Consider replacing the battery with a new one if you note either of the following conditions The battery run time drops below about 80 of the original run time The battery charge time increases significantly 6 3 Cleaning If necessary clean the Li lon battery with a soft dry cloth Never use liquids solvents or abrasives to clean the Li lon battery 6 4 Maintenance The Li lon battery is maintenance free Charge the battery to approximately 5096 of its capacity at least once every 2 years to pre
33. y batteries If a defective battery is is present in the series found replace it Disconnect all loads and connect a charger to the battery Then press the reset button for at least 5 seconds to resolve the fault condition The reset button can be found in the fuse compartment see paragraph 2 7 The battery has been discharged to deeply causing the battery management system to trigger the external switch off device The BMS is now in fault condition lithium batteries Problem Possible reason Solution Disconnect the charger from the battery and press the reset button for at least 5 seconds to resolve the fault condition The reset button can be found in the fuse compartment see paragraph 2 7 The battery has been overcharged causing the battery management system to trigger the external switch off device The BMS is now in fault condition Disconnect the charger from the battery and press the reset button for at least 5 seconds to resolve the fault condition The reset button can be found in the fuse compartment see paragraph 2 7 Drain the battery then equalize the battery s cells as described in paragraph 5 2 4 The batteries cells have has become unbalanced During charging one or more cells overcharge causing the battery management system to trigger the external switch off device The BMS is now in fault condition Disconnect the c
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