User Manual for 80V/12F Modules
Contents
1. Mounting holes are designed for M6 hardware 2 Torque on compressive loads should not exceed 30Ncm Alternative Mounting Options Please check with your loxus Representative if you have unique requirements here is an example of what can be done to meet your needs Toll Free 1 877 751 4222 Fax 607 433 9014 http www ioxus com sales ioxus com 2013 Ioxus Inc All rights reserved oS IOXUS INC r 18 Stadium Circle OX U S Oneonta NY 13820 Environment For best results modules should not be exposed directly to the environment particularly the avoidance of direct splashes should be considered In systems with voltages greater than 60V protection of the terminals to avoid shock and corrosion should be instituted Modules that are expected to see significant cycling should be mounted in free air or in forced ventilation housing Care should be taken to protect modules in potentially corrosive environments and direct water splash or spray is should be avoided In all environments the best possible performance is aided by using an anti oxidation agent on the aluminum terminals No Al Ox or other similar products are appropriate and highly recommended for all terminal connections Careful design consideration should be given to the application to prevent the overheating of the modules Temperature monitoring is optionally available and discussed later in this document P2. 4 Ifthe voltage is under 2V connect the shorting wire provided by Ioxus to the and connectors 5 The module is now safe for handling Leave the shorting wire connected at all times Accessories Module accessories such as mating connectors and terminal hardware are available for order Custom cables bus bars and monitoring connections are available on request but may require an NRE charge and will require all relevant mounting considerations in order to design your product Please contact your Ioxus representative with questions or requests Operation All modules should only be operated within their prescribed voltage constant current and temperature operating window These should be monitored to ensure the safe operation and long life of your module NOTE Operation of module above 65C will void the warranty Maintenance The modules should be kept free of dust and debris and cleaned at a regular interval In inside locations that should be no more than annually however this may vary with your particular circumstances Outside location will be as needed Once the modules are discharged proceed with cleaning with a cloth and a simple water soap solution Avoid the use of hoses or pressurized Toll Free 1 877 751 4222 Fax 607 433 9014 http www ioxus com sales ioxus com 2013 Ioxus Inc All rights reserved An IOXUS INC a 18 Stadium Circle OX S Oneonta NY 13820 sprays Once the assembly is clean check for properl
3. 80V modules can be mounted in any orientation and are qualified for shock and vibration as is detailed on the applicable datasheet Please review the datasheet and test specifications to determine the appropriateness of the module for your application The modules should not be mounted anywhere where the frame member mounted to applies any stress torque or twisting to the module housing All mounting holes are located on the end plates and should be mounted to points that are in plane with each other or parallel to each other for Rack mount applications Shims and spacers should be used if any of the mounting points are more than 4imm out of plane 8mm hardware of a grade appropriate for the application should be used for standard 80V modules In addition it is best to avoid mounting on or near significant heat sources such as engine exhausts or solar heated panels Mounting Details for Preassembled Modules 8 20 THRU FOR M8 BOLT 290 ors a ed e I i i d Doo O a L Dimension 80V 12F Dimension 80V 12F 12F 160V 6F 240V AF 320V 3F 400V 24F 2 4F 480V 2 AF Requires center plate in same location as 240V 105 2 1802 255 2 330 2 405 2 483 4 module Toll Free 1 877 751 4222 Fax 607 433 9014 http www ioxus com sales ioxus com 2013 Ioxus Inc All rights reserved SS IOXUS INC a 18 Stadium Circle OX S Oneonta NY 13820 Mounting for Individual Modules
4. AL EE EE EA EE EE EE 14 Toll Free 1 877 751 4222 Fax 607 433 9014 http www ioxus com sales ioxus com 2013 Ioxus Inc All rights reserved oS IOXUS INC a 18 Stadium Circle OX U S Oneonta NY 13820 Never touch the power terminals as any residual voltage can cause fatal electrical shocks Always check with a calibrated meter that the module is discharged prior to handling the module please see the step by step instructions in this manual for the discharge procedure Warranty Limitation Ioxus modules are unserviceable property of the customer and if opened or otherwise modified are no longer covered by any warranty written or implied Introduction Ioxus modules represented in this document are designed for a wide variety of applications from stationary back up power to transportation usage Each module is built with welded bus bars and internal balancing circuitry The balancing circuitry can be one of several formats based on the options selected The standard balancing circuitry for the large format modules is a 2 stage active balancing that will be described later in the document The balancing circuitry is built in and protected by the aluminum housing allowing the entire structure to be rugged and also meet the water resistance requirements of IEC 60529 IP54 The specifications and recommended configurations suggested in this manual are subject to change and should be verified by checking the most recent version of thi
5. An IOXUS INC a 18 Stadium Circle OX U S Oneonta NY 13820 User Manual for 80V 12F Modules Models e iMODO80V12P1M XXA IMODO80V012 02A IMODOSOVO12P1M OOA Toll Free 1 877 751 4222 Fax 607 433 9014 http www ioxus com sales ioxus com 2013 Ioxus Inc All rights reserved SS IOXUS INC a 18 Stadium Circle OX S Oneonta NY 13820 Table of Contents Models o E EE cece AE OIE COON EE RE NE OE EE EE AK N 3 Module Part Numbering and it s Meaning seeccccssssssseececcccccccccsseesececeeccccccssssssesee 4 EO CUS AE EE EE E EE d UNDA dig ie EEN DE OE RE RE EO EE EE EE EE OE EE 4 male ale AE EE EE N 4 pies die OR E EE A A E 5 Orientation and ADDU CAC ORE iS edel N GE ee ERG Eg ok RR ee oe Ee RE se ee De eek bee 5 Mounting Details for Preassembled Modules sees ee ee ee ee ee ee RR RR ek ek ee Re Reed 5 Mounting for Individual Modules ooo ESEG ne ede ee Re oe es GO Ie Gede ed oe eed ee oe ee 6 Alternative Mounting ODtONS ees sesse se ek Re ee ee RR ee ee ee ee ee Ge RR ee ee RR GR ee Ge Ge RR Re ee ee ee ee Reggie 6 SAAGIS LEE ee OE EE EE EE 7 NI pe ie ie EE EEN EL OE EE EE EE ON EE OR EE EE EG 8 Mieta lae kie ARE ER EE EE EE EE EO N EE OE EE EE EE N 9 BaN ye N OE EN EE Sarel AE N ER EE EE A 12 Blei gel die EE OE RR RE EE OR EET 12 PEC io EE EE EE EE 13 Opera ON ER EE EE N E E EON E 13 Mamnte nae E ME EE N EE EE 13 FE SC OMG RNG MR EE AE EE EA EE EE 14 OS ER OE EE EE EE EE EE EE 14 DISPOS
6. ers possible module voltage rating in Volts three digits M for module i for IOXUS Logistics Unpacking Please inspect the shipping carton for signs of damage prior to unpacking the carton Report any damage to the carton or the contents to the carrier immediately Retain all shipping materials until the module is fully inspected and determined to be operational The module should be lifted by the module body The terminals should not used for hoisting The terminal shorting wire should remain in place If any parts are determined to be missing or defective an RMA number must be issued prior to returning the unit for repair or replacement Please contact your salesperson or distributor to request an RMA number Handling Ultracapacitor modules are designed for years of maintenance free operation if handled installed and used properly These handling precautions should be observed e The modules should not be stacked unless still in original packaging Toll Free 1 877 751 4222 Fax 607 433 9014 http www ioxus com sales ioxus com 2013 Ioxus Inc All rights reserved SS IOXUS INC a 18 Stadium Circle OX S Oneonta NY 13820 e The only tools to be used on the module should be properly sized wrenches for the terminal and mounting bolts hammers chisels files or power tools in general should not be used e Do not drop modules invisible internal damage mage occur Installation Orientation and Application
7. lease refer to the operational temperature range on the data sheet and be sure to allow for Toll Free 1 877 751 4222 Fax 607 433 9014 http www ioxus com sales ioxus com 2013 Ioxus Inc All rights reserved An IOXUS INC a 18 Stadium Circle OX S Oneonta NY 13820 internal heating of the modules If you require help with the design considerations and sizing please contact your representative for assistance Venting Please note a venting hole is built into each module and a filler bolt is fitted to it If external venting is required remove the M5 bolt and fit with appropriate plumbing to relocate the vent Electrical Modules can be mounted in series and or parallel with each other Care should be taken to insure that similar capacitance and ESR modules are used for series chains and that if different type or age modules are used in parallel configurations the differences in ESR are accounted for in your design Appropriate size bus bars or cables and terminals should be used for the application Please note that to minimize system loses the capacitors do not have fusing or internal circuit breakers careful consideration in the system design should be taken to prevent over current With the low ESR of the capacitors they can deliver very large amounts of current A grounding strap should be installed on each module The worst case fault current should be considered when sizing the wire for this application It is recommended
8. nc All rights reserved An IOXUS INC a 18 Stadium Circle OX U S Oneonta NY 13820 Pin 4 Pin 5 Reserved Stop Col Pin 3 Pin 6 Overtemp Emt Reserved Pin 2 Pin 7 Reserved Stop Emt Pin 1 Pin 8 Overtemp cal Reserved E o Digital Outputs are continuously parallel able they can be paralleled across parallel and series module connections x Figure 1 Module with Monitoring Installed Additional constraint of cabling may be required for your application Toll Free 1 877 751 4222 Fax 607 433 9014 http www ioxus com sales ioxus com 2013 Ioxus Inc All rights reserved SS IOXUS INC a 18 Stadium Circle OX S Oneonta NY 13820 02X Digital overvoltage and over temperature Over Voltage Collector Reserved Over Voltage Emmiter o 8 Reserved o Over temperature caution triggered when the sensor measure greater than 60C internal module temperature o 2 monitoring output connectors are fully parallel no priority This allows several modules to be monitored with only 2 or in fact 1 monitoring circuit if you are not concerned which event causes the warning Digital Voltage or Temperature Warning To MCU Low Pins 3 or 77 Balancing The standard balancing for the 350F cell based modules is passive system This is a rugged and reliable system and accomplished by hardwiring 1200 1 resistors in parallel with each cell This will drive the cells to conve
9. rgence on a float charged system rapidly reduce voltage on an overvoltage cell and discharge the module for service over about 24 hours Toll Free 1 877 751 4222 Fax 607 433 9014 http www ioxus com sales ioxus com 2013 Ioxus Inc All rights reserved SS IOXUS INC a 18 Stadium Circle OX U S Oneonta NY 13820 Safety Never touch the power terminals as any residual voltage can cause fatal electrical shocks Always check with a calibrated meter that the module is discharged prior to handling the module please see the step by step instructions in this manual for the discharge procedure e Prior to installation or removal the module and or system of modules must be discharged fully and shorting wires installed procedure below e Provide sufficient electrical isolation for operation above 50VDC e Protect surrounding electrical and conductive components from incidental contact e Do not operate above specified voltage or temperature range e Do not touch terminals while charged serious burns shock or material fusing may occur Discharging 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 12V for an 80V module and is enough to cause dangerous electrical shocks and other undesirable consequences Toll Free 1 877 751 4222 Fax 607 433 9014 http www ioxus com sales ioxus com 2013 Ioxus Inc All rights reser
10. s document and the product datasheets on www IOXUS com Please keep note of your model number when referencing this manual and note if each section refers to your specific model number If your model has an output connector specifications for that connector and how to use each connection will be detailed in the appropriate sections below Toll Free 1 877 751 4222 Fax 607 433 9014 http www ioxus com sales ioxus com 2013 Ioxus Inc All rights reserved _ IOXUS INC 18 Stadium Circle OX S Oneonta NY 13820 Module Part Numbering and it s Meaning Hro PPP bheg e SLEE ra Numeric for F roto Option Codes Numeric for standard Alpha for customer specials sss i sSSC Alpha for customer specials sss i sSSC customer specials separator used for readability Cell Terminal Type Terminal Cell Terminal Type Cell Type Cell Type P for passive P for passive balancing w o clamping P for passive balancing w o clamping clamping Capacitance Capacitance value rounded to the nearest Farad three digits rounded to the nearest Farad Capacitance value rounded to the nearest Farad three digits digits V V for voltage for multiples of 6 cells round down to closest multiple of 16 V for voltage for multiples of 6 cells round down to closest multiple of 16 for multiples of 6 cells round down to closest multiple of 16 B for TIT w single stage clamping X for no balancing oth
11. to remove the anodizing or coating if applied on the housing at one of the bolting points to allow for the ground strap to be properly installed Thread locking should be done with star washers or an appropriate chemical thread locker used on threaded portion of terminal bolt not the electrical connection in no case should flat washers be used with lock washers Care should be taken in cable routing to not impose undue forces torques or tensions on the module terminals Only appropriately sized ring terminals or bus bars for the expected currents should be used Toll Free 1 877 751 4222 Fax 607 433 9014 http www ioxus com sales ioxus com 2013 Ioxus Inc All rights reserved oS IOXUS INC a 18 Stadium Circle OX U S Oneonta NY 13820 Power Connections Configured as 400V module Series Connections Monitoring There are 2 types of available monitoring configurations noted by the suffix on the part number for your module s 1 00X No Monitoring 2 02X Digital overvoltage caution digital over temperature caution e General Specifications for monitoring 02X o Operating Voltage 5 24V Max 80V o Overvoltage output Digital open collector Trigger if any group of 3 cells exceeds 8 25V 2 75V cell o Max operating current o 3mA o MFG part number for mating connector RJ45 s Contacts 8 o Pin out Diagram Toll Free 1 877 751 4222 Fax 607 433 9014 http www ioxus com sales ioxus com 2013 Ioxus I
12. ved SS IOXUS INC a 18 Stadium Circle OX S Oneonta NY 13820 Prior to any maintenance or replacement each module should be individually discharged and shorted with a resistor or wire Even a fully discharged module can rebound naturally to an unsafe condition Be sure to discharge with an appropriately sized resistor or resistor bank not provided and either keep that resistor attached or replace it with a shorting wire or bus bar when the module is depleted Be sure to check the voltage with a calibrated meter prior to attaching the shorting device The voltage should be 00 25V 1 Using a voltmeter measure the voltage between the 2 terminals 2 The pack will naturally discharge to below 5V because of the passive balancing in lt 48hours 3 Ifthe 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 48V for a 4 Ohm pack the module will be initially discharged with a current of 15A and will take about 15 minutes to fully discharge However in this case the heat power dissipated in the resistor pack will be 1 2kW 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
13. y torqued fasteners and note any damage to any of the housings or signs of internal damage and replace as necessary In high vibration applications fasteners used for mounting as well as electrical connections should be checked for torque every 6 months Reconditioning This module does not require condition because of the passive balancing system 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 Disposal Please recycle according to local codes and regulations for flammable materials Toll Free 1 877 751 4222 Fax 607 433 9014 http www ioxus com sales ioxus com 2013 Ioxus Inc All rights reserved
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