Bar code - EV Power
Contents
1. Product Owner Manual Terminals Safety valve and Bar COC Cie yo ce 1 Disclainie T oensesspir 16 Terminals cece cece cee eeeeee l E E 5 NOX oaia EO 17 Bal COJE tis chantidareduidceubtiennes 3 Charging amp discharging requirements 000000 4 Installation amp Maintenance 6 Basic Requirements for Battery WiSCall Alon 22302 6205 525 014 eee cscs 6 Basic Requirements for Battery CONNEC CHOU ecco wnceadanecnd eueacenees 7 Basic requirements for battery storage and maintenance 9 Failure treatment 10 Quality Assurance 14 Introduction II Attentions before Using Using this manual It is really appreciated that you To quickly locate information about choosing the Lithium battery that the battery use the Index in the back made by CALB Please read this of the manual It is an alphabetical instruction carefully before using the list of what is in the manual and the battery In order to make sure of page number where it can be found using correctly please keep this service manual carefully for future reference The users should read this manual carefully familiar with the charging and discharging characteristics understand the usage of BMS and charging generator before using the batteries Danger Warnings and Cautions Warning message found in this manual describe hazards and what to do avoid or reduce them2. Danger indicates a hazard with a high level of risk which will result in serious injury Warning or Cautions indicates a hazard that could result in damage to the battery or injury human body This means there is something that could hurt you or other people Notice This means that something II Introduction could result in property or battery damage This would not be covered by the battery s warranty A circle with a slash through it is a safety symbol that means Do not do this or Do not let this happen Terminals Safety valve and Barcode 1 Terminals Please polish the terminals with CA40 abrasive paper when assembling CA60 the batteries CA100 CA180 M amp x16 Do not twist the terminal under any circumstance It is forbidden CA400 M14x16 ANXS500 M14x16 The positive terminal is made of aluminum and the negative terminal is made of copper Both of them are soft metals be careful when assembling the batteries Notice The terminals may oxidize tighten the bolts to standard t aaa in the air with longtime storage we suggested below 2 Terminals Safety valve and Bar code Safety valve The safety valve will automatically open and close Do not open the valve it is forbidden The safety valve is used to release the internal pressure to avoid body swollen Notice The safety valve could prevent the water in the air getting into the battery Bar
3. checking and maintaining the batteries periodically not Index 17 B B r O0C carecas inca idandceves 3 C CPA INE aeree E e ETEEN 4 COMNeECctiON ccceceecececeees 7 D Dischi Moerisia enie 4 Disclaimer csccececeee 16 I Installation c ccceceeeees 6 M Maintenance 0ceceeeeeees 9 Quality Assurance 4 14 S Salety Valve errora iin aao 2 SOFI Ersan eia 9 TermiiNal Seene l EMAIL service calb cn Troubleshooting 0065 10 TEL 0379 60697962 TOE eenean E 1 FAX 0379 65196088 W Working temperature 5 The final explanation rights of the manual are reserved by CALB CALB will edit this document occasionally A modified document is provided to customers only with the package CALB does not undertake the responsibility of notifying the original customer All of the users could search for solutions on our website or through technical service
4. code Bar code is the only identification of one battery It consists of 16 digits including 3 digits of area code 3 digits of capacity code 6 digits of production date and 4 digits of serial number Specific Instructions are as follows 1 Area Code NSA means America Space EU means Europe and Space AP means Asia Africa or Australia 2 Capacity Code It is the number of the battery s capacity For example the capacity code of CAIOOFT is 100 3 Production Date Manufacturing Department mainly confirmed the date Same date with a batch of batteries 1s suggested The Date format is year mouth day For example Dec 2 2010 that is 101202 which generally for the date of production 4 Serial Number Based on the amount of batteries 4 digits in all Such as the serial number of the 20th battery is 0020 Notice The bar code is the only certificate of identification it is required to show when warranty Please keep the bar code in good condition Terminals Safety valve and Bar code 3 4 Charging amp discharging requirements Charging amp discharging requirements Addition to the special description the following is the charging amp discharging parameter 1 The constant charging voltage for individual cell is 3 65V It also can be used in CCCV charging mode when getting into CV model The constant charging voltage of a pack is Nx3 65V N means the numbe
5. crease the motor power when cell s temperature rise up to 50 C and shut down the motor when the Charging amp discharging requirements cell s temperature rise up to 55 C 5 6 Installation amp Maintenance Basic Requirements for Battery Installation 1 Each group of batteries must be properly fixed to the battery box and stand directly Changing the placement direction is not recommended 2 When using the battery modular group fixture provided by our company make sure to tighten flat mattress and spring mattress on the rod assemble and tighten the nut completely to ensure the battery pack maintain clamping state during the bumping driving process The pack in the compartment should keep 30mm 50mm space at the top to facilitate the connection of a battery management system wiring harness and repair lines also for better heat elimination Installation amp Maintenance 7 4 When clamped battery modules are installed inside of the battery cabinet the bottom and all around of batteries shall be lay with a layer of elastic items such as rubber for shock absorption the installation of battery cabinet on the frame shall take appropriate vibration reduction measures 5 Consider cooling measures for designing the layout and installation of batteries and battery cabinets Battery cooling methods can be varied with the most basic one of adopting fan cooling Consider air flow p
6. heets please replace the busbar 4 Once the battery has been over discharged accidentally you could try to repair it as follows 1 First charging the battery with lower than 0 1C current 2 When the cell s voltage rises up to 3 2V you could charge it with higher current 3 If the cell s voltage can t rise up to 3 2V with long time charging Please replace it with the backup battery 5 Once you reverse charging the cells please replace the cells with substitutions Make sure the new cell gains the same SOC with other cells 6 If you have any other technical problem welcome to contact the customer service department Failure treatment 11 Emergency processing The electrolyte of lithium ion power battery is lithium salts organic solvents which is corrosive being damage if disclosure incurs If it is inadvertently leaked the following first aid measures shall be taken 1 Release measures 1 Method 1 If electrolyte leaks on the shell surface you need to wear corrosion protective gloves wipe with a cloth impregnated with alcohol and to dry 12 Failure treatment 2 Method 2 If electrolyte reliefs from safety valve in washing with plenty of water for 15 minutes Turn to medical treatment if it 1s serious the form of gaseous immediately evacuate the people present wear gas masks and insulated gloves turn the battery upside down 2 Eye contact quickly r
7. inse eyes with the side having valve with plenty of water for more down in a dry plastic buckets than 15 minutes during which lift then immediately transfer the the upper and lower eyelids Turn barrel to ventilation to medical treatment if it 1s environment Serious 4 Inhalation move to ventilated place Oxygen as needed Turn to medical treatment if it 1s serious 5 Ingestion take orally 2 cups milk or water Vomitoria is forbidden under unconscious Turn to medical treatment if it 1s serious 3 Skin contact remove clothes Failure treatment 13 14 Quality Assurance Quality Assurance 1 CALB provide three years warranty of the batteries If batteries cannot be used because of the quality and is in accord with the exchanging requirement CALB will exchange them for free including the round trip freight 2 Barcode will be used to identify the cell when offering warranty CALB will not be responsible for customer service if there 1s no barcode Notice If one cell was sold to the market out of the area as it s marked in the barcode CALB won t offer warranty According to the area code the representative office which is in charge of this area will solve the problem Head office of CALB will not be responsible for after sale service directly Before setting up the overseas representative office head office of CALB is in charge of the after sale service direc
8. onditions are consistent as far as possible temperature differentials must not exceed 5C 10 Failure treatment Troubleshooting Methods 1 Great attention must be paid to the security of repair maintenance Operations and construction of high voltage battery pack Beware of electric shock 2 The positive terminal is made of aluminum material and the negative terminal is made of copper Please obey the rules provided at Terminals when you screwing the bolts Notice If the screw thread was broken that can t tight the bolt repairing is not allowed please contact the customer service of CALB 3 During the process of charging and discharging in particular high current charge and discharge the battery if BMS detected any certain individual battery voltage fluctuated widely and was markedly different from other batteries please check on it carefully 1 Whether you have tightened YY 2 3 4 5 the bolt on the terminals 1f not please tighten it Whether the oxide layer on the surface of the battery s two polarity pole has been wiped off if not use sand paper to clean it Whether the BMS voltage acquisition line is reliable please correct the fact connection if not Whether there are problems of connection across compartment or over length of wire Large tolerance will be caused by high voltage depreciation If there is oxide layer between busbar s
9. r of the batteries in the pack Notice In order to prevent over charging the charger shall automatic convert to CV model when any individual cell s voltage rise up to 3 65V 2 When the charging current of CCCV model lower than 0 05C charging process shall be stopped The maximum charging voltage for individual cell is 3 8V Charging process must be stopped immediately when any cell s voltage rise up to 3 8V Over charging will cause irreparable damage to the battery also with high level of risk that will result in injury human body 4 The floating charge voltage for Individual cell is 3 40V The floating charge voltage for pack is Nx3 4V N means the number of the batteries in the pack 5 The minimal discharging voltage is 2 5V When the temperature is below 20 C it is 2 0V Notice The depth of discharge is more than 90 when an individual cell s voltage falls down to 3 0V it is nearly exhausted Please charge your pack as quickly as possible If anyone cell s voltage falls down to 2 0V Discharging process must be cut off immediately Longtime over discharge Will cause irreparable damage to he battery 6 Working temperature The working temperature range for charging is 0 C 40 C and the working temperature range for discharging is 20 C 50 C Notice BMS shall be able to boot the cooling fan when the cell s temperature rises up to 40 C and de
10. roblems of vehicle at run time when designing you can also drum the cold air of train carriage Basic Requirements for Battery Connection Power supply modules or or air conditioning system into the battery compartment in order to achieve the purpose of cooling batteries batteries installation must be operated by trained professionals Installations must be operated strictly in accordance with the relevant work instruction manual It is necessary to put on insulating gloves when packing 3 The metallic tools such as socket the batteries wrench screwdriver and fixed wrench must be insulated by electrical tape Installation amp Maintenance cause great damage to human the battery pack body and the batteries Pay attention to the metal items 5 Please sanding the battery s 8 Please tighten the bolts to carrying on such as key chains terminals before packing them avoid increasing the contract watches necklaces etc Never l ct contact those metal items to the that could remove the oxide layer Reo ee may cau and reduce the contact resistance 9 The cell s terminals are made of in short circuit 6 After batteries group selection soft metals please do not use battery pole shall be taken excessive force when tighten the 4 Be careful when packing the insulated protection measures bolts and do not strip the screw thread batteries Great attention must be 7 Be sure
11. tative office will mark record and store these problematic batteries in certain places for future recollection 5 The quality assurance period for newly exchanged battery is based on the date of previous ones Customers must fill in the Battery Quality Issue Feedback Sheet first and also offer the photos or data of unqualified batteries 16 Disclaimer Disclaimer CALB shall not undertake the cost which caused by users inappropriate usage of the products as follows 1 Using or testing batteries without reliable BMS or PCB which cause part short circuit or over discharge 2 Revering charges the cells which destroy the cells 3 Not effectively controlling the charging process which over charge the cells 4 Not effectively controlling the discharging process which over discharge the cells 5 Not selecting appropriate cable connector lug and other electrical components which cause safety removing the accident potential issues by over heat on time Not installing high voltage protection component within main loop Damage the device by damaged and aging of the wire Adopting the connection method which affect the SOC balance of battery pack exp support devices with the power from some of the cells which may cause over discharge of some cells Wrong connection between cable lug and bus bar decrease the life span by over heat which caused by loosen of the bolt Not
12. tly The battery warranty period is 36 months from the date of shipping out of factory If there are warranty terms in the contract please follow the contract Identification method the identification must be proceeded by CALB s Customer Service Department or the third party authority admitted by CALB The fare will be paid by customers in advance The result of the identification shows that if batteries do have quality problems CALB will pay the fare and send money back to customers in cash or some other ways if not customers will pay instead Methods for quality assurance 1 In the quality assurance period if the batteries cannot be used because of its quality problem please first contact the technician in the nearest representative office for consultancy 2 After the confirmation from 3 YY the technicians please send the problematic battery to the representative office At the Same time the technicians there would give relevant feedback to the CALB s Customer Service Department After the representative office receives the abnormal battery it will have them tested and if it does have a problem an email with an application for exchanging battery will be sent to Customer Service Department and then report to the manager in Marketing Department The problematic battery will be exchanged after the confirmation by the Quality Assurance 15 manager 4 The represen
13. to install the quick acting paid to avoiding short circuit and fuse or DC air breaker in the wrong connection which may main circuit in order to protect Installation amp Maintenance 9 Basic requirements for battery storage and maintenance 1 The batteries should be stored at temperature of 5 40 C dry clean and well ventilated warehouse 2 Batteries in using or in inventory should be excluded from direct sunlight and be away from the heat sources at a distance of no less than 2m If it has to be allocated near the heat source then the proper insulation measures should be taken Take full account of water flooded shock resistance for battery cabinet s layout Batteries shall be stored in boxes or flat laid with insulated material and marked clearly Battery in inventory shall not be placed upside down or lying Mechanical shock or stress and cells exposed to heat and rain is strictly prohibited Formulate the tracking table for battery in inventory Checking the battery s voltage every month and record on the tracking table Notice If the cell s voltage is lower than 3 0V it is nearly exhausted Please charge the cells with 0 3C for one hour as soon as possible 7 Fully charge and discharge the cells every six months with 0 3C and record the result 8 When considering the battery layout make sure batteries external environment especially ambient temperature c
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