USER MANUAL - Tecate Group
Contents
1. detailed description of the communication protocol please refer to the document Maxwell Technologies CAN Communication Specification document number 1014339 3 2 4 1 2 Analog Monitoring Configuration B33 The temperature output is via a PT100 RTD temperature sensor The resistance of the RTD varies with temperature to provide actual temperature of the module The resistance measured through the RTD relates to temperature according to the temperature chart in table 1 4 for the Minco resistance 17624PDYT15BC EN60751 Class B 100 Ohm 0 C http www minco com Table 3 13 RTD function diagram for the 125 V Module 3 2 4 Fan Connection The 125 V modules are cooled by two 12 V or 24 V DC axial cooling fans The fans each have two 30 5mm 22 gauge 0 64mm wires for electrical interconnection red positive black negative The wires are un terminated to allow for maximum customer flexibility in providing power and connection to the fans The fans can draw up to 2 3A each 4 Thermal Considerations Low internal resistance of the energy storage modules results in relatively low internal heat generation within the modules during use However the high demands of heavy transportation warrant the use of heat sinks and cooling fans to keep the cells at a low uniform temperature Operating the module at a temperature above 65 C will void the module warranty As with all electronic components ultracapacitors have a longer service life2. Page 17 Document no 1014343 5 2008 Maxwell Technologies Inc Maxwell Technologies Inc Worldwide Headquarters 9244 Balboa Avenue San Diego CA 92123 USA Phone 1 858 503 3300 Fax 1 858 503 3301 Contact Information Maxwell Technologies SA Maxwell Technologies CH 1728 Rossens GmbH Switzerland Brucker Strasse 21 Phone 41 0 26 411 85 00 D 82205 Gilching Fax 41 0 26 411 85 05 Germany Phone 49 0 8105 24 16 10 Fax 49 0 8105 24 16 19 info maxwell com www maxwell com User Manual BMOD0063 version 2 2 Document no 1014343 2008 Maxwell Technologies Inc H Maxwell Maxwell Technologies Inc Shanghai Representative Office Rm 2104 Suncome Liauw s Plaza 738 Shang Cheng Road Pudong New Area Shanghai 200120 P R China Phone 86 21 5836 5733 Fax 86 21 5836 5620
3. half pack voltages is similar to what it was before the conditioning process was performed the indication is that the module is functioning normally Excessive divergent voltage rates in the halves or step functions in the half pack voltages which cause them to separate will indicate possible defect conditions in the pack A 5 pin mating connector for the monitor output is provided as part of the accessory kit see Section 5 for part numbers 22 gauge wire may be used to make cables up to 6 feet 1 8 m in length For lengths longer than 6 feet 1 8 m shielded wire is recommended 3 2 4 Temperature Monitoring 3 2 4 1 Temperature Sensors The 125 V module uses a temperature sensor within the module at a location which is representative of the cell population temperature See Figure 3 12 for a diagram of the temperature sensor location on the 125 V module User Manual BMOD0063 version 2 2 Page 13 Document no 1014343 5 2008 Maxwell Technologies Inc H Maxwell TEMPERATURE SENSOR AIRFLOW IS LOCATED ON THE DIRECTION FRONT CENTER CELL Figure 3 12 Temperature Sensor Diagram for the 125 V Module 3 2 4 1 2 Digital Monitoring The CAN Monitor measures the temperature and sends the value over the CAN bus to the network master The CAN Monitor also compares the measured temperature to pre set warning and alarm levels If the temperature is outside of the operating range a flag will be set as an indication to the master For
4. of the assembly For the front assembly it is recommended to measure the length of the section of cables inside the junction box to make sure they will properly fit and provide enough slack Then unplug the pin power connectors tighten the 2 fittings and re plug the pins at both power terminal locations User Manual BMOD0063 version 2 2 Page 8 Document no 1014343 5 2008 Maxwell Technologies Inc H Maxwell Alternately for multi module implementations with short cables the junction box can be mounted on the module after cable insertion fitting and crimping 12 Install the lid and tighten the 4x M4 screw and washers with a torque of 3 Nm Apply Loctite 271 provided to screws before installing Figure 3 10 Lid assembly on the junction box CANBus cables not to scale Connection of modules in series or parallel should be done with the same gauge wire as determined for final output connections When connecting in series connect the positive output terminal of one module to the negative output terminal of the next module Parallel arrangements require tee connections in the cable not supplied Up to twelve 12 125 V modules may be connected in series for high voltage applications This corresponds to a maximum system voltage of 1500 VDC Isolation of the modules is tested to 4000 VDC The modules should not be used in higher voltage environments If higher voltage is desired please contact your Maxwell rep
5. the reconditioning cycle from point 1 above In the chance event that the voltages do not converge during the reconditioning cycle the active balancing electronics is not functioning correctly Please contact your Maxwell application sales engineer for further assistance 3 2 3 Analog Monitor Configuration B33 A DANGER HIGH VOLTAGE HAZARD Never touch any of the tap pins as the module can be charged and cause fatal electrical shocks Always check that the module is fully discharged before manipulating the module Please refer to the step by step instructions below for the manual discharge procedure 3 2 3 1 Connection User Manual BMOD0063 version 2 2 Page 11 Document no 1014343 5 2008 Maxwell Technologies Inc H Maxwell A single 5 pin connector on the front panel of the heavy transportation modules carries signals for temperature monitoring and center tap voltage monitoring Figure 3 11 shows the pin assignment on the 5 pin 7KVA panel mounted monitoring connector of the 125 V module Y 5 Pin Assignment Center Tap Voltage Positive Tap Voltage Temeprature Sensor Lead 1 or 2 Temperature Sensor Lead 2 or 1 Negative Tap Voltage AWIN Figure 3 11 Pin assignment for 5 pin module panel mounted monitoring connector 3 2 3 2 Voltage Monitoring The 125 V modules use 3 pins in the 5 pin connector for positive pin 2 negative pin 5 and center tap pin 1 v
6. when kept at a lower temperature The thermal resistance RA of the units has been experimentally determined assuming forced convection at ambient 25 C The R value provided on the data sheet is useful for determining the operating limits for the units Using the Ry value User Manual BMOD0063 version 2 2 Page 14 Document no 1014343 5 2008 Maxwell Technologies Inc H Maxwell a module temperature rise can be determined based upon any current and duty cycle The temperature rise can be expressed by the following equation AT I R Ryd Where I current amperes Resr resistance ohms Rin thermal resistance C W d duty cycle fraction This AT plus ambient should remain below the specified maximum operating temperature for the module as measured by the RTD output 5 Accessories The accessory kit is included with 125 V heavy transportation modules and contains the following Part Number Description Quantity 107686 M18 fittings 2 107687 M18 fittings Nuts 2 107941 Power terminal male male swivel adapters 2 108585 Male pin female crimp power connectors 2 107690 Lug connectors with plastic isolation cover 2 107940 Junction box with seals 1 107642 Junction box lid 1 108222 Connector 8 pos plug DTM 1 108223 Connector 8 pos rec DTM 1 108230 Wedgelock for DTM06 1 108231 Wedgelock for DTM04 1 104995 Contact solid pin Deutsch 5 104998
7. CAN communication as the direct reading is the difference only within a particular User Manual BMOD0063 version 2 2 Page 10 Document no 1014343 5 2008 Maxwell Technologies Inc H Maxwell module It should be compared to the table values below If the difference in voltages exceeds the table value a reconditioning cycle should be performed Series Connected Reconditioning Triggers Number of Modules in Series Peak Delta Voltage Trigger 1 3 0V 2 3 4 5 6 to 12 2 6V This is the value which sets the flag in CAN communications for each module The reconditioning cycle is the following 1 Charge the series of modules to 129 6 V x Number of Modules in Series for 5 minutes Monitor the 8 cell string voltages and the Peak Delta Voltage as reported via the CAN bus 2 Disable Disconnect the charging source Ensure that no leakage current occurs between the charging source and the module 3 Monitor the 8 cell string voltages and peak delta voltage using the CAN bus The voltage management circuits will work to reduce the cell voltage Check the peak delta voltage when each module voltage has drained to about 125 V or when the total voltage across all series connected modules is Nx125V This should take about 10 15 min If the peak delta is now lower than 1 V the reconditioning is finished and the module can be put back in operation If the peak delta voltage is larger than 1V redo
8. Contact solid socket Deutsch 5 107693 Screw TORX M4 0 7x10mm Zinc Plated 8 107990 Screw SHCS M5 0 8X20 CLASS 12 9 Plated 8 106583 Washer Lock 10 SS 8 106775 Washer Lock M4 SS 8 107993 Loctite 271 1 107728 Mating Monitor Connector 1 CAN version B04 B14 B24 only Analog version B33 only 6 Operation The heavy transportation modules should only be operated within specified voltage and temperature ratings Determine whether current limiting is necessary on input output based on current ratings of ancillary devices Observe polarity indicated on module User Manual BMOD0063 version 2 2 Page 15 Document no 1014343 5 2008 Maxwell Technologies Inc 7 H Maxwell Safety Wan DANGER HIGH VOLTAGE HAZARD Never touch the power terminals as the module can be charged and cause fatal electrical shocks Always check that the module is fully discharged before manipulating the module Please refer to the step by step instructions below for the manual discharge procedure e Do not operate unit above specified voltage e Do not operate unit above specified temperature rating e Do not touch terminals with conductors while charged Serious burns shock or material fusing may occur e Protect surrounding electrical components from incidental contact e Provide sufficient electrical isolation when working above 50 V DC e Prior to installation on and removal from the vehicle or equi
9. Maxwell TECHNOLOGIES USER MANUAL Maxwell Technologies BOOSTCAP Energy Storage Modules for Heavy Duty Transportation Applications User Manual for 125 V Modules with CAN Communication Protocol BMOD0063 P125 B24 22 BMOD0063 P125 B14 22 BMOD0063 P125 B04 22 BMOD0063 P125 B33 22 Revision 5 TECHNOLOGIES H Maxwell warning A DANGER HIGH VOLTAGE HAZARD Never touch the power terminals as the module can be charged and cause fatal electrical shocks Always check that the module is fully discharged before manipulating the module Please refer to the step by step instructions in the Safety section of this manual for the manual discharge procedure WARRANTY LIMITATION Do not open or modify the module Opened or modified modules are no longer covered by warranty and are unserviceable property of the customer 1 Introduction The 125 V heavy transportation modules are self contained energy storage devices comprised of 48 individual ultracapacitor cells The modules include bus bar connections and integral voltage management circuitry Units may be connected in series to obtain higher operating voltages parallel to provide additional energy storage or a combination of series parallel arrangements for higher voltages and energy 125 V modules must never be connected to other types of modules in any way Thermal monitoring and electronic voltage management circuitry is incorporated into each of the heavy transp
10. and bracket locations Retain the shipping materials until the unit has been inspected and is determined to be operational The User Manual BMOD0063 version 2 2 Page 1 Document no 1014343 5 2008 Maxwell Technologies Inc H Maxwell original shipping materials are approved for both air and ground shipment Make sure that the shipping container s contains the following 1 Heavy Transportation Module 2 Accessory Box a Fan Shroud Assembly 12V or 24V b Accessory Kit including junction box 3 User Manual If the unit is found to be defective or any parts are missing contact the factory A Return Material Authorization RMA number must be issued prior to returning the unit for repair or replacement 3 Installation 3 1 Mechanical The heavy transportation modules can be mounted in multiple orientations and requires the proper hardware to be used Good high voltage electrical practices should be observed in design of the module installation The supported orientations are Horizontal straight Vertical on the longer side For this orientation the module needs to be bolted to a supporting wall or structure Any angle between horizontal straight and vertical on the longer side The module must be properly bolted to a supporting structure and the top of the module must face upward The mounting surfaces on the bottom angles are designed to support the module with no additional mechanical contact Fastener
11. cription of the communication protocol please refer to the document Maxwell Technologies CAN Communication Specification 1014339 The latest version of the communication protocol and this manual can be downloaded at http www maxwell com Every pack will have a unique separation of voltages across the 8 cell string due to differences in cell capacitances interconnect resistance variances and other native cell contributions Therefore the pack should be measured for its baseline condition which should have a variance of less than 3 V when first energized after the module is received from the factory The difference in the 8 cell string voltages should be regularly monitored during use as it is can be used as a performance indicator for that module If the voltage across any two 8 cell strings diverge from each other over use and time such that the voltage difference is greater than 3V the monitor sends a warning flag via the CAN bus When this happens a reconditioning cycle should be applied in order to bring the strings back into better balance When multiple N modules are connected in series the voltages of all 8 cell strings N x 6 measurements should be monitored through the CAN communications Calculate the difference between the maximum string voltage measured and the minimum string voltage measured This difference is the Peak Delta Voltage for the system This is different than the Peak Delta Voltage which can be read through
12. ed with the proper diameter drill both cable holes at the desired location on the junction box housing or junction box lid Maxwell provides 2x M25 fittings but diameters up to M32 can be supported by the junction box The 2 holes can be on any of the 4 sides or on the lid of the junction box depending on the customer s implementation in vehicle Figure 3 3 Junction box with 2 holes Holes may be drilled on any side or on the cover User Manual BMOD0063 version 2 2 Page 5 Document no 1014343 5 2008 Maxwell Technologies Inc H Maxwell 3 Install the 2x M25 fittings in the holes Figure 3 4 Fittings assembly 4 Trim the power cables not provided to the appropriate lengths 5 Install the junction box housing and fasten it to the front panel using the 8x M5 screws and 10 washers with a 6 N m torque Apply Loctite 271 provided to the screws before installing Figure 3 5 Junction box assembly on the module CANBus cables not to scale User Manual BMOD0063 version 2 2 Page 6 Document no 1014343 5 2008 Maxwell Technologies Inc H Maxwell 6 Insert both cables into the junction box through the fittings Te Figure 3 6 Customer cables insertion in the junction box CANBus cables not to scale 7 Install the 90 swivel adapters at both terminal locations on the fron
13. ersion 2 2 Page 16 Document no 1014343 5 2008 Maxwell Technologies Inc H Maxwell 8 Maintenance Prior to removal from the vehicle cable removal or any other handling ensure that the energy storage module is completely discharged in a safe manner The stored energy and the voltage levels may be lethal if mishandling occurs 8 1 Fan Maintenance The 125 V module uses Orion fans model OD172SAP 24HBXC 55 24 V or OD172SAP 12HBXC 55 12 V The expected life of the fans based on L10 life is 65 000 hours at 45 L10 life is defined as the time when 10 of the sample could be expected to fail The customer is responsible for monitoring fan operation if desired It is recommended to monitor cell temperature as an indication of fan performance Damage to cells as a result of fan failure is not covered under warranty 8 2 Module Conditioning Please refer to section 3 2 2 2 9 Storage The module can be stored in the original package discharged in a dry place Observe the maximum storage temperature as stated in the specifications Discharge used module prior to stock or shipment The shorting wire shipped with the unit should be retained for use during storage to prevent charge from accumulating in the module 10 Disposal Do not dispose of module in trash Dispose of according to local regulations 11 Specifications Refer to data sheets for specifications for each specific product User Manual BMOD0063 version 2 2
14. es Inc H Maxwell LOWER L 03 MIN EFT MOUNTING HOLE 4x 010 0 THRU NEXT MODULE 0 0 35 Earthing Stud p Se r H eamm kT LOWER LEFT MOUNTING HOLE FIRSTMODULE Top View End View Figure 3 1 125 V Installation Dimensions One of the sides A B or C must be completely unobstructed and adjacent to ambient air on both the inlet and exhaust sides of the module CANBus cables are not to scale The 125 V module is installed onto the vehicle first then the fan shroud assembly is installed onto the module with screws provided The handles may then be removed if desired Refer to Figures 3 2 for exploded views of the modules and fan shroud assemblies Re assembly of the fans in the opposite direction in order to provide reversed air flow is at this point neither recommended nor supported Note The mounting envelope is specified in order to provide adequate space for cooling air to enter and exit the module Failure to provide space for cooling air will cause the module to operate at a higher temperature and therefore reduce the life of the capacitors Additional minimum space of 66mm will also be required in front of the module to allow for the high power electrical cables Flexible electrical cable such as finely stranded or welding cable must be used to achieve the necessary bend radius If stiffer cable is used additional clearance will be required in front of the module When installing multiple modu
15. ilities Note The chassis of the module must be connected to system ground through the earthing stud size M10 1 25 located on right side of the module see figure 3 1 with large enough gauge wire to carry the worst case fault current or directly through the mechanical mounting points and into the vehicle chassis Customer should supply a nut with these threads and also use of a lock washer is recommended User Manual BMOD0063 version 2 2 Page 4 Document no 1014343 5 2008 Maxwell Technologies Inc H Maxwell 3 2 1 High Power Connection The high power electrical connections are made within a sealed junction box mounted to the front of the module The connectors also use proprietary Radsok contacts which provide low insertion force and reliable low resistance capability These connectors must be mated with the correct Amphenol lugs available in the accessory kit see Section 5 for part numbers The mating connectors accept cables with a maximum conductor OD of 11 1mm 90 degree connector or 9 1mm straight connector If using another size the cable should have the correct size amp temp rating for the application current Cables which are too small can add a significant amount of resistance to the installation reducing system efficiency and generating heat The following steps need to be taken in order to properly assemble the junction box and power connections 1 Unpack the accessory kit 2 Using a holesaw not provid
16. les in series or parallel configurations refer to Figures 3 1 for proper hole spacing Modules may be stacked vertically only if attached to individual support structures Leave 25mm clearance minimum between modules Refer to section 3 2 1 for electrical information on series and parallel configurations User Manual BMOD0063 version 2 2 Page 3 Document no 1014343 5 2008 Maxwell Technologies Inc H Maxwell 4X M8 MOUNTING SCREWS NOT SUPPLIED X SCREW M6 X 16mm WITH LOCK WASHERS AN SHROUD ASSEMBLY Figure 3 2 125 V module with fans not included with model B04 3 2 Electrical A DANGER To avoid arcing and sparking the energy storage module should be in a discharged state and the system power disconnected during installation The module is shipped discharged and with a shorting resistor wire The shorting wire should be removed just prior to making electrical connections For more information about the discharge procedure please refer to section 7 Safety To provide the lowest possible equivalent series resistance ESR the high power current path within the heavy transportation module is not fused Care should be taken within the application to prevent excessive current flow as required Excessive current and or abnormal duty cycle will result in overheating the module which will cause irreparable damage Please consult the specific data sheet for each module for current and duty cycle capab
17. oltage monitoring The center tap voltage is a monitoring capability that provides an indication of relative distribution of cell voltages in the module separated into two halves In design of the corresponding measurement circuit the output impedance of these monitoring connections should be taken into account The output impedance provides a safety margin In case of a short to ground the maximum current will be than 10mA Ro 150 kohm 5 Cee Pin 2 Ro 150 kohm 5 Pin 1 Ro 150 kohm 5 S Pin 5 Vtotal Vmi Vm2 Where Vtotal is the measurement from the positive input to the negative output of the module Vmi is the measurement from the positive input to the center tap Vm2 is the measurement from the center tap to the negative output It is recommended that the measurement circuit have an input impedance of at least 100 times the output impedance of the device being measured If the input impedance is lower than this a scaling factor will need to be applied User Manual BMOD0063 version 2 2 Page 12 Document no 1014343 5 2008 Maxwell Technologies Inc H Maxwell Voutput Vmeasured x Rinput Routput Rinput Every pack will have a unique separation of the two halves due to differences in cell capacitance interconnect resistance variances initial state of charge separations native cell leakage current variations and other known contributions Therefore the pack should be meas
18. ortation modules The voltage management circuitry functions primarily to protect every cell from operating in a damaging over voltage condition The module is equipped with Maxwell Voltage Monitoring System This system monitors the voltages of six 6 groups of 8 cell strings as well as the temperature The values of these measurements can be retrieved by CAN communication The heavy transportation module is built with heavy duty extruded aluminum enclosures The modules are cooled using two DC axial fans and two large finned heat sinks which make up the top and bottom of the enclosure Sheet metal shrouds make up the air passage and direct the cooling air over the heat sinks The module is permanently sealed water resistant per IEC 60529 IP65 and require no internal maintenance The power terminals are fully enclosed in a water resistant junction box The low voltage CAN connectors chassis vent and earth ground stud are selected to be suitable for heavy transportation environments 2 Unpacking Inspect the shipping crate for signs of damage prior to unpacking the module Damage to the shipping crate or module should be reported to the carrier immediately Remove the module from the shipping crate by removing the lag screws and lifting the module straight up by the lifting handles or lifting brackets The 125V module weighs 56 kg without accessories and fans and can be lifted by hand by two people Please refer to figure 3 2 for handles
19. pment it is mandatory to fully discharge the module to guarantee the safety of the personnel A A fully discharged module may bounce back if it is stored without a shorting wire connected to the and terminals This bounce back can be as much as 15V for the 125V module and is enough to cause dangerous electrical shocks Proceed as follow to discharge the module 1 2 Using a voltmeter measure the voltage between the 2 terminals If the voltage is above 2V a resistor pack not supplied with the module will need to be connected between the terminals Proper care needs to be taken in the design and construction of such a dissipative pack e g At 125V for a 4 Ohm pack the module will be discharged with a current of 31 25A and will take about 20 minutes to fully discharge However in this case the heat power dissipated in the resistor pack will be 3 9kW The resistor pack will need to be sized and provided with suitable cooling to handle this power dissipation Additionally proper enclosure or other packaging is necessary to ensure safety In all cases proper design of the dissipative resistor pack is necessary If the voltage is under 2V connect the shorting wire provided by Maxwell to the and connectors The module is now safe for handling However leave the shorting wire connected at all times until the module is installed in the vehicle the power cables are connected User Manual BMOD0063 v
20. resentative When several modules are connected in series for operating at higher voltage care must be taken to ensure proper creepage and clearance distances in compliance with national safety standards for electrical equipment 3 2 2 CAN Monitor Configuration B04 B14 B24 CAN Bus communications protocols data formats and commands are covered in a separate manual For a detailed description of the communication protocol please refer to the document Maxwell Technologies CAN Communication Specification document number 1014339 The latest version may be found at http www maxwell com 3 2 2 1 Connection The HTM125 Ultracapacitor Module is equipped with two 8 pin Deutsch connectors each on a short cable One of the connectors is a Socket Plug and one is a Pin Receptacle for easy daisy chaining User Manual BMOD0063 version 2 2 Page 9 Document no 1014343 5 2008 Maxwell Technologies Inc H Maxwell Connector Type Socket Plug Pin Receptacle Drawing Overview Connector PN DTM06 08SA DTM04 08PA Wedgelock PN WM 8S WM 8D Socket Pin PN 0460 202 20141 0462 201 20141 Connector Pin Out CAN_H CAN_L SHIELD NC NC NC 24 RIN 24 VDC H 5 INIA AIWwWIN 3 2 2 2 Voltage Monitoring The CAN Monitor measures the voltage from the negative terminal to every 8 cell and transmits the values over the CAN bus to the network master For a detailed des
21. s must be Class 12 9 or stronger must be torqued properly and must include flat washers and locking devices The following fasteners not supplied are recommended for attaching the modules to the vehicle 4 screws M8 1 25 x 20 mm long Please note that longer screws may be required if using through holes and nuts Note Maxwell Technologies specifications and warranty apply only when mounting the module using the feet as assembled at the factory Removal of the feet and mounting directly to the body of the module voids the warranty Should the module be mounted without the factory supplied feet mounting points are detailed in document 1014553 available by download at http www maxwell com the user is required to provide shock and vibration test data to re validate the warranty Refer to Figures 3 1 below for overall module dimensions mounting envelope and mounting hole locations The use of alternate module mounting orientations or custom feet other than those provided by Maxwell Technologies will result in voiding the warranty unless such uses have been disclosed to Maxwell and approved by Maxwell by express written consent prior to implementation Zones 1 inlet and 2 exhaust are reserved for cooling air One of the sides A B or C must be completely un obstructed and adjacent to ambient air on both the inlet and exhaust sides of the module User Manual BMOD0063 version 2 2 Page 2 Document no 1014343 5 2008 Maxwell Technologi
22. t panel of the module Swivel adapters are required to accommodate variation in cable lengths and allow mechanical relief of the assembly This step is not required for front installation a Sa Figure 3 7 Swivel adapters insertion in the junction box CANBus cables not to scale 8 Crimp the lugs onto both cables When connecting multiple units together make sure that both ends of the cables are installed in both junction boxes prior to crimping 9 Depending on the location of holes creepage and clearance distances between the 2 terminals User Manual BMOD0063 version 2 2 Page 7 Document no 1014343 5 2008 Maxwell Technologies Inc H Maxwell may be too short and require extra isolation To maintain the proper creepage distance for an operating voltage of 1000V we recommend at least 19 1 mm through air For this purpose install and clip the plastic covers around both cable lugs This step is not required for front installation Ga dg Ith ice AO AU ER Worl Figure 3 8 Swivel adapters cover assembly CANBus cables not down 10 Connect both power cable lugs to the respective terminal pins by pressing them in all the way Figure 3 9 Final connector assembly CANBus cables not to scale 11 For the side assembly tighten the 2 fittings to ensure proper stability and water resistance
23. ured for its baseline condition which should have a variance of less than 4 V when first energized after the module is received from the factory The difference in the half pack voltages should be regularly monitored during use as it is a performance indicator for that module and may change as the module ages A monitoring frequency of once per day would be sufficient may be less frequent depending on the application Little value will be gained by monitoring more frequently If the two halves of the pack diverge from each other over use and time such that the voltage difference between halves is greater than 6V a reconditioning cycle should be applied in order to bring the halves back into better balance The reconditioning will not only bring the halves back to balance but also can help determine the cause of this divergence The reconditioning cycle is the following Charge the module to 129 6 V or the module string to 129 6V x number of modules in series and hold on charge for 5 minutes At this time measure the half pack voltages Given effective working voltage management circuitry the half pack voltages will be below the 4 V maximum range after conditioning If that is not the case contact your applications engineer for further information If that is the case then the module can be put back into service Monitoring of the half pack voltages can then resume as was the case before exceeding the 6 V limits Assuming the rate of change of the two
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