Think A306 Service Manual
Contents
1. lt coa ER Exit Figure 3 Flash Tool Service Manual Think A306 Page 23 of 32 Ener1 Lithium Power Systems 06 10001 rev 00 Rev Date 29 JAN 2011 4 4 4 5 4 3 5 9 Diagnostics Interface Under Development 2 quarter 2011 implementation planned Step 3 Using Information provided Ener1 will evaluate possible solutions and implement a plan Step 4 Ener1 will implement the best solution Service Manual Think A306 Page 24 of 32 Ener1 Lithium Power Systems 06 10001 rev 00 Rev Date 29 JAN 2011 5 Appendix A 5 1 Acronyms and Terms Acronym or Term Definition BDM Background Debug Mode BMS Battery Management System BOB Break out Box BOM Bill of Material DAC Data Acquisition Card EPO Emergency Power Off FIS Factory Information System FT Functional Test FTS Functional Test Station GPIB General Purpose Interface Bus HPPC Hybrid Pulse Power Characterization HV High Voltage HW Hardware ICT In circuit Test 1 0 Inputs and Outputs LBS Lithium Battery Systems LEC Lithium Energy Controller LV Low Voltage MLEC Master LEC MTS Manufacturing Test Specification PC Personal Computer PCB Printed Circuit Board PS Power Supply RLEC Remote LEC SMT Surface Mount Technology SOP Start of Production SW Software UART Universal Asynchronous Receiver Transmitter USB Universal Serial Bus UUT Unit Under Test WIP Work in Process XFMR Transformer Service Manual Think A306 Page 25 of 32 Ener1 Lithium2. Pack is sent by L customer to Ener1 Service Center nter process includes testing charge discharge etc A Failure confirmed via 5 NTF customer Eneri council determines final disposition of the claim and implements OP10009 and OP10010 if required Service Manual Think A306 Ener1 Lithium Power Systems 06 10001 rev 00 Page 14 of 32 Rev Date 29 JAN 2011 4 2 4 3 4 3 1 4 3 2 Step 1 Contact Eneri USA Ben Wrightsman Bill Hayes Field Service Manager Field Service Engineer Ener1 Ener1 15425 Herriman Blvd 15425 Herriman Blvd Noblesville IN 46060 Noblesville IN 46060 Mobile 317 383 7089 Mobile 317 435 0931 bwrightsman ener1 com bhayes ener1 com Europe Tomasz Poznar Europe Field Manager Eneri Europe 29 rue de Bassano Paris France 75007 Mobile 48 604 833 933 tpoznar ener1 com General Reference only Ener1 Lithium Power Systems 8740 Hague Road Indianapolis IN 46256 Ph 317 585 3400 Fax 317 585 3444 www ener1 com Step 2 Defining and Analyzing a problem Detailed look at tools available for analysis TBD Comm Tool usage CAUTION DO NOT REMOVE COVER OR ANY PANELS FROM PACK Traceability Tracking Requirements Traceability of the packs through the manufacturing processes is required Deep traceability is required for each component and component of each subassembly to track back to as early as a particular lot a
3. extinguishers are preferred Dry Chemical extinguisher may also be used U Fire may generate irritating and or toxic gas 3 5 Transporter Safety Information Packages that are crushed punctured or torn open should not be transported These packages should be isolated until the shipper provides instructions and if appropriate arranges to have the product inspected and repacked In the event that damage to the packaging results in the release of batteries the spilled contents should be immediately collected and segregated absorb with earth sand or other non combustible material per ERG Emergency Response Guide Guide 147 The shipper should be contacted for instructions Service Manual Think A306 Ener1 Lithium Power Systems 06 10001 rev 00 Rev Date 29 JAN 2011 Page 12 of 32 4 Service Response Plans How Customer should respond in the event of a battery pack issue 4 1 Flow Chart following page Level Who Typical problems 1 Local Dealer NTF Malf codes Broken R MLECs 2 Ener1 Fuses Current Technician Sensors Contactors Cables Mechanical damage 3 Ener1 lab corrosion overheating water ingress How Diagnose amp S W update Replace BMS component Rework Where Dealer Dealer Ener 1 lab Logistic Remote support phone email Ener1 Travel Ship battery pack to Ener1 Service Manual Think A306 Page 13 of 32 Ener1 Lithium Power System
4. sal PN B 36 313030 sal PN Rev 3030 800t ID 01010003 300t PNJA 423132 30 Soot_PN_B 41414141 300t PN Rev 3030 Figure 2 Comm Tool Service Manual Think A306 Page 18 of 32 Ener1 Lithium Power Systems 06 10001 rev 00 Rev Date 29 JAN 2011 Note Contactor Condition Codes and Highest Error Reasons detailed in the Vehicle CAN Bus Guide 90 10017 for Msg EDL_Data00 CAN msg ID 610 are identified by DECIMAL values The HEX data determined during pack diagnostics must be converted from HEX to DECIMAL before cross referencing to the DECIMAL values For illustration purposes a copy of Contactor Condition Codes and Highest Error Reasons from Vehicle CAN Bus Guide 90 10017 associated with MLEC Application Software is shown below BMS Contactor Conditions Code Present Status Decimal values Designators S Service Category Fault K Key Cycle Category Fault 0 Conditions OK 1 Loss Of Emergency Power Off Signal K 2 All Internal Slave Data Not Received 3 Cell Over Voltage K 4 Cell Under Voltage K 5 Pack Over Current K 6 Pack Over Temperature K 7 Pack Under Temperature K 8 Circuit Board Over Temperature K 9 PreCharge Retry Fault K 10 PreCharge Short Circuit Fault K 11 No PCU Data Received Messages 310 and 311 K 12 Airbag Deployed K 13 Fuel Cutoff Crash Event Notification K 14 PCU Fault 15 Isolation Fault With Contactors On K 16 Isolation Fault With Contactors Off K 17
5. E AN EE dean cala 15 4 3 5 1 PACK INTERFACE TOO St id t 15 4 3 5 2 PACK DIAGNOSTICS SOFTWARE APLLICATIONS cee eee cee eueeeecueeuaueeeuaes 16 4 3 5 32P CAN WIEWER A a a 16 4354 GOMM TOO Lie cede states aadeeides e e e e ee ta 16 4 3 5 5 COMM TOOL VS CAN MESSAGE STRUCTURE 0 0cccseecee see eeeeeeeeuuaeseeueesaeeeeunaneues 19 4 3 5 6 MLEC APPLICATION CODE PROGRAMMI NG cess eeceeseeeeeceeeeseeeeeeeeeenene ees 21 4 3 5 7 BATTERY PACK APPLICATION SOFTWARE RE PROGRAMMI NG aaa aaa aaa 21 43 50 FLASHNLOOL savas sen te A te hte Ae dana 22 4 3 5 9 DIAGNOSTIC INTEREACE is A e Cae Ven i 23 4 4 STEP 3 PLAN EVALUATION 0 c0ccccccccccceeceeeecececeeeaeeeeeseceeecueeaueeseseeeeseaaeauaesseeeeeeseauaaseseeeeeeeauauseeeeeeesaeeaneneess 23 45 Step 4 Plan implementation i nanen eee cece eee eee eee eper tepri peptike 23 Di APPENDDOA 2 A a A ER TOA 24 5 1 AGRONYMS AND RERMS La it e Ia tt dei iaa td 24 61 APPENDIX Bi iniciada aleate 25 6 1 ENER1 INTERNAL REFERENCE DOCUMENTS TO ACCOMPANY SERVICE MANUAL 0000seceseeseeeeeeeeseeeeseeeeanees 25 6 2 EXTERNAL REFERENCE DOCUMENTS raniona ea anaa a a eiaa ea adka daadaa haodar ad 25 6 2 1 EMERGENCY RESPONSE GUIDE ERG 2008B 00ooocococcconccccocccononanononcnanocccnncnnnnnnnnnn nn enen ee teket eee eee 25 6 2 1 1 CONTACTANOS e 26 6 2 1 2 GUIDE 147 LITHIUM ION BATTERIES oooccccccccncnononocnncnnnonononannnnnncnnnnonnnnnnnnnnnnnnnn eee eee eee kek i eres eve e teve kie 28 6
6. Figure 1 Msg 300 byte 2 is 22 hex this information indicates MLEC Build 22 Application Software Msg 610 byte 6 is 13 hex this information indicates the Contactor Condition Code to be a 19 Service Category Fault contactors locked out until service fault codes cleared 6 0 00 7 1200 2 8 00 00 00 00 00 00 00 00 200 42 8 02 00 22 00 00 00 01 00 1001 8 8 00 00 00 17 00 58 00 DC 200 42 8 00 00 00 00 09 54 00 00 200 42 8 OF 59 00 00 00 00 00 00 200 42 8 00 00 00 00 00 E6 00 D2 200 42 8 00 00 00 40 00 00 00 00 200 42 8 00 00 00 00 00 00 00 00 1000 8 3 00 00 00 200 42 2 00 00 200 42 8 06 72 06 58 17 15 13 00 200 42 S 2A aes RP te TATE NETET Figure 1 PCAN Viewer 4 3 5 4 Comm Tool In Figure 2 Software_ID byte 0 is XX hex this information indicates MLEC Build XX Application Software i e 25 hex Build 25 Service Manual Think A306 Page 17 of 32 Ener1 Lithium Power Systems 06 10001 rev 00 Rev Date 29 JAN 2011 a Oo 00 Com Port F1 5701 14 Send Single UseCAN Rev Range com4 x Cen Al Mai Codes Message F DisplayRawData C Baud Rate 38400 v V Using Conv Box M Sec13 Large Print T Repeat Every 2 TA Select Master Sequence File C Documents and Settings tony taylor My Doc T Log Data Every Jo L Sec EM Software ID 01020025 Spp_PN_A 40 314150 Spp_PN_B 41 33 30 36 pp PN Rev 3030 al PNJA 4D 41 33 30
7. Low Voltage Pack Recover Mode 18 Key Cycle Category Fault Contactors locked out til next key cycle 19 Service Category Fault Contactors locked out til service faults codes cleared 20 Circuit Board Under Temperature K 21 Powerup Self Test Fail K 22 No CAN Contactor Request Not used for A306 23 Secondary_ContB_Or_FuseB_Fault K 24 Contactor 1 Stuck On Fault S 25 Contactor 2 Stuck On Fault S 26 Fuel Cell Iso Fault Not used for A306 27 Secondary Contactor Stuck On Fault K 28 Latched Contactor Fault Not used for A306 29 Cont_1_Dropout_Fault K 30 Contactors_Engaged_During_Shutdown Not used for A306 31 Cont 2 Dropout Fault K 32 Cont 1 Stuck Open Fault K 33 Cont 2 Stuck Open Fault K 34 Secondary ConiB Or FuseB Fault K 35 Pack Overcurrent Regulation Fault K 36 Aux Batt Undervoltage _ Fault 37 Discharge During Charge Fault K Service Manual Think A306 Page 19 of 32 Ener1 Lithium Power Systems 06 10001 rev 00 29 JAN 2011 BMS Highest Err Reason Most recently detected error Decimal values Designators S Service Category Fault No Error PCU Fault No Charge Current Circuit Board Temperature Warning Current Limit On Low Temperature Current Limit On High Temperature External Isolation Fault Internal Isolation Fault Fuel Cutoff Crash Event Notification Airbag Deployed 10 No PCU Data Received Messages 310 and 311 11 PreCharge Short Circuit Fault 12 PreCharge Retry Fault
8. Power Systems 06 10001 rev 00 Rev Date 29 JAN 2011 6 Appendix B 6 1 Enerl Internal Reference Documents to accompany Service Manual Section Number Reference Description P N pO E i 6 2 External Reference Documents Guidelines are reference only please contact local authorities in case of an emergency 6 2 1 Emergency Response Guide ERG 2008 Service Manual Think A306 Ener1 Lithium Power Systems 06 10001 rev 00 Rev Date Page 26 of 32 29 JAN 2011 6 2 1 1 Contact Info UNITED STATES 1 CHEMTREC a 24 hour emergency response communication service can be reached as follows CALL CHEMTREC 24 hours 1 800 424 9300 Toll free in the U S Canada and the U S Virgin Islands For calls originating elsewhere 703 527 3887 Collect calls are accepted 2 CHEMTEL INC a 24 hour emergency response communication service can be reached as follows CALL CHEMTEL INC 24 hours 1 888 255 3924 Toll free in the U S Canada Puerto Rico and the U S Virgin Islands For calls originating elsewhere 813 248 0585 Collect calls are accepted 3 INFOTRAC a 24 hour emergency response communication service can be reached as follows CALL INFOTRAC 24 hours 1 800 535 5053 Toll free in the U S Canada and the U S Virgin Islands For calls originating elsewhere 352 323 3500 Collect calls are accepted 4 3E COMPANY a 24 hour emergency response communication service can be reached as
9. may burn but none ignite readily Vapors from liquefied gas are initially heavier than air and spread along ground Some of ihese materials may react violently with water Cylinders exposed to fire may vent and release toxic and or corrosive gas through pressure relief devices Containers may explode when heated Ruptured cylinders may rocket PUBLIC SAFETY CALL Emergency Response Telephone Number on Shipping Paper first If Shipping Paper not available or no answer refer to appropriate telephone number listed on the inside back cover As an immediate precautionary measure isolate spill or leak area for at least 100 meters 330 feet in all directions Keep unauthorized personnel away Stay upwind Many gases are heavier than air and will spread along ground and collect in low or confined areas sewers basemenis tanks Keep out of low areas Ventilate closed spaces before entering ROTECTIVE CLOTHING Wear positive pressure self contained breathing apparatus SCBA Wear chemical protective clothing that is specifically recommended by the manufacturer It may provide little or no thermal protection Structural firefighters protective clothing provides limited protection in fire situations ONLY itis not effective in spill situations where direct contact with the substance is possible ACUATION Spill See Table 1 Initial Isolation and Protective Action Distances for highlighted materials For non highlighted materi
10. 2 1 3 GUIDE 125 GASES CORROSIVE maa ananas sa e ne nonen ste eeee re eee et este eere si nete este se rere anes teste sete ni neve este eren 30 END OF DOCUMENT MARKER vi cdo acas coca si sudec dan d n oe sr onde nan s ov s Poet ss Plav s ee es Nard dat ntveeeeeteadsacazevesecesdaaects sacs 32 Service Manual Think A306 Page 3 of 32 Ener1 Lithium Power Systems 06 10001 rev 00 Rev Date 29 JAN 2011 TABLE OF FIGURES le tata aaa 16 Figure 2 Comm Tool ara IE ROA ara ho 17 Figures Flash TOO ceci E N h n bet kd ba Ee E s het 22 Service Manual Think A306 Page 4 of 32 Ener1 Lithium Power Systems 06 10001 rev 00 Rev Date 29 JAN 2011 1 Manual Overview 1 1 General Pack Ratings 8 Specifications Reference Document 04 10004 1 2 Battery Pack Safety Precautions when working around a HV battery pack 1 3 Lithium Safety Information Hazardous material considerations Reference Ener1 Material Safety Data Sheet MSDS 07 10001 1 4 Service Response Plan How customer should respond in the event of a battery pack issue Ener1 Contact Defining and Analyzing a problem Details of tools available Ener1 will evaluate and plan Ener1 will implement a solution Pon Service Manual Think A306 Page 5 of 32 Ener1 Lithium Power Systems 06 10001 rev 00 Rev Date 29 JAN 2011 General Pack Ratings amp Specifications 2 1 Rated Specifications Specification Remarks Pack configuration 96 cells in ser
11. 29 JAN 2011 End of Document Marker This Block Marks the End of This Document
12. H 002022 Mfr PEAK System www peak system com Vendor PHYTEC www phytec com Software Service Introduction of software service and installation diagnostics and programming 4 3 5 1 Pack interface tools gt BOB Break out Box w LV pack interface harness Custom hardware that can be attached inserted at the pack LV connector to provide direct access to LV signals during development and debug gt PCAN Tool w Viewer and or Explorer Off the shelf hardware and software application s that provides a method for CAN bus connectivity and communication gt Comm Tool Proprietary hardware and software application that supports Mode 1 communication mode Y ELSI communication is supported for the Comm Tool hardware Y CAN communication is supported for the PCAN Tool hardware gt Programming Tool Proprietary software application that provides a method for application code reprogramming v ELSI communication is supported for the Comm Tool hardware Y CAN communication is supported for the PCAN Tool hardware Service Manual Think A306 Page 16 of 32 Ener1 Lithium Power Systems 06 10001 rev 00 Rev Date 29 JAN 2011 4 3 5 2 Pack diagnostics Software applications gt PCAN Viewer gt PCAN Explorer DBC files gt Comm Tool LAB MSP files A CAN Interface Tool PCAN USB Adapter with optical isolation can be connected to CAN H and CAN L of the Vehicle CAN Bus at the OBD II connector 4 3 5 3 PCAN Viewer In
13. OONDOOARWN O 13 Circuit Board Over Temperature Fault 14 Pack Under Temperature Fault 15 Pack Over Temperature Fault 16 Pack Over Current Fault 17 Cell Under Voltage Fault 18 Cell Over Voltage Fault 19 Contactor 2 Stuck On Fault 20 Secondary Contactor Open Fault 21 Loss Of Emergency Power Off Signal 22 Circuit Board Under Temperature Fault 23 Contactor 1 Stuck On Fault 24 Slave Data Not Received Fit 25 Powerup Self Test Fit 26 Secondary Contactor Stuck On Fit 27 Contactor Dropout Fit 28 Fan Current Low Fit 29 Fan Current High Fit 30 Aux_Batt_Under_Volt_Flt 31 Conti Stuck Open Fit 32 Cont2 Stuck Open Fit 33 DChg During Chg Fit 34 Key Cycle Category Fit 35 Service Category Fit 36 High Cont Coil Gur Fit 4 3 5 5 Comm Tool vs CAN message structure gt Comm Tool display represents malfunction codes as 4 byte hex values with byte 0 on the right gt CAN messages are typically shown with byte 0 on the left and display byte values from left to right Comm Tool Malf Code Long Word 1 00 00 00 00 lt byte 0 bit 0 Malf Code Long Word 2 00 00 00 00 lt byte 4 bit 0 CAN message Data0 Data1 Data2 Data3 Data4 Data5 Data6 Data7 00 00 00 00 00 00 00 00 A A byte O bit 0 byte 4 bit 0 Service Manual Ener1 Lithium Power Systems Think A306 06 10001 rev 00 Rev Date Note Malfunction Codes diagnostic flags are detailed in the Vehicle CAN Bus Guide for each of the following specific CAN me
14. TB_OPEN_FLT Secondary contactor B or fuse B fault Bit5 37 NO_PCU_DATA_FLT No PCU data received fault Bit6 38 OVER_CURRENT_REG_FLT Pack over current regulation fault Bit7 39 IN 12V UNDER VOLT FLT 12V input under voltage fault Bito 40 LO DCHG DURING CHG FLT Low level discharge during charge fault Bit 1 41 HI DCHG_DURING_CHG_FLT High level discharge during charge fault Bit2 42 SLAVE_COMM_FLT Internal slave data not received fault Bit3 43 STRING_V_MISMATCH_FLT String voltages have excessive disparity Bit4 44 IN 12V UV VVARNING 12V input under voltage vvarning Bit5 45 HI CONT COIL CUR FLT High contactor coil current fault Bit6 Not used Bit 7 Not used Bit 0 Not used Bit 1 Not used Bit 2 Not used Bit 3 Not used Bit 4 Not used Bit 5 Not used Bit 6 Not used Bit 7 Not used Bit O Not used Bit 1 Not used Bit 2 Not used Bit 3 Not used Bit 4 Not used Bit 5 Not used Bit 6 Not used Bit 7 Not used 4 3 5 6 MLEC programming of application code gt Bootloader and pack end model compatibility gt Current offset and gain values in EEPROM unique at pack characterization v default settings v transfer of CURRENT OFFSET settings gt Malfunction codes Key Cycle and Service category faults v Clear codes 4 3 5 7 Battery Pack Application Software Re Programming Install the re flash application software known as Flash Tool Connect the CAN Interface Tool PCAN USB Adapter with optical i
15. als increase in the downwind direction as necessary the isolation distance shown under PUBLIC SAFETY Fire If tank rail car or tank truck is involved in a fire ISOLATE for 1600 meters 1 mile in all directions also consider initial evacuation for 1600 meters 1 mile in all directions Service Manual Think A306 Page 31 of 32 Ener1 Lithium Power Systems 06 10001 rev 00 Rev Date 29 JAN 2011 ERG Guidelines for safety EMERGENCY RESPONSE FIRE Small Fire Dry chemical or CO Large Fire Water spray fog or regular foam Move containers from fire area if you can do it without risk Do not get water inside containers Damaged cylinders should be handled only by specialists Fire involving Tanks Fight fire from maximum distance or use unmanned hose holders or monitor nozzles Cool containers with flooding quantities of water until well after fire is out Donot direct water at source of leak or safety devices icing may occur Withdraw immediately in case of rising sound from venting safety devices or discoloration of tank ALWAYS stay away from tanks engulfed in fire SPILL OR LEAK Fully encapsulating vapor protective clothing should be worn for spills and leaks with no fire Do not touch or walk through spilled material Stopleak if you can do it without risk Ifpossible turn leaking containers so that gas escapes rather than liquid Prevent entry into waterways sewer
16. er and service personnel Bypassing or forcing these systems to operate in a way other than by design may result in injury or death Ener1 bears no responsibility for your failure to operate the systems in accordance with this guide and is not liable for any resulting damages whatsoever DANGER HIGH VOLTAGE SYSTEM There are no user serviceable parts inside of pack case Pack safety systems are intended to protect users from injury DO NOT TAMPER WITH PACK CONNECTORS OR REMOVE ANY PANELS OR COVERS FROM THE SYSTEM DO NOT INSERT FINGERS OR ANY OTHER OBJECTS INTO THE PACK CASE THROUGH ANY OPENINGS PORTS OR SEAL INTERFACES FAILURE TO COMPLY MAY RESULT IN SEVERE INJURY OR DEATH AND ENER1 IS NOT LIABLE FOR ANY RESULTING INJURIES OR DAMAGES WHATSOEVER AS A RESULT OF A FAILURE TO COMPLY WITH THESE TERMS Battery Pack Cells Major cell components are Q Anode LI Cathode Q Separator O Electrolyte Cells are prismatic flat and tightly sealed around all sides to prevent leakage A damaged cell can leak flammable vapors from the electrolyte 1 These vapors should be contained within the pack unless there is significant damage to the pack case AU Even low levels of vapor escaping from the pack will give off a distinctive odor OU Extreme caution should be used to prevent any spark generation in the vicinity of a damaged pack venting electrolyte vapors Safety Considerations only Ener1 certified technicians should be working internally o
17. f CAN Msg ID 300 Byte 2 received from the battery pack Example 02 00 25 00 00 00 01 00 indicates MLEC Build 25 Application Software in the battery pack v The Ener1 proprietary Comm Tool application software can also be used to verify the new MLEC Application Software Build The Master Sequence File PartNum MSP will display the MLEC Application Software Build in Software_ID Byte 0 Example 01 02 00 25 indicates MLEC Build 25 Application Software in the battery pack Q Turn Key Run OFF Q Disconnect the 2 wire CAN Interface Cable from Vehicle CAN H and CAN L at the vehicle OBD On Board Diagnostic connector U Re flash procedure is complete NOTE If the battery pack is not installed in a vehicle Vehicle CAN H and CAN L and Key Run may be accessed directly at the LV connector of the battery pack 4 3 5 8 Flash Tool In Figure 3 MLEC Application Software has been re flashed successfully Sherali Dod dieti jci ad a C C 2 C EneDenMLec_A306_25 s19 Browse C C gt C Checksum 791E C IV Use CAN I Verbose CAN Rev Range Remote 400 400 61E 61F CAN KBaud 500 Transmission C Manualmode Auto mode Reception Response Erasing application flash allow up to 15 seconds Command accepted Programming and Verifying Data Block 984 Requesting application checksum Checksum matches file Resetting target Command accepted Checking software type Application code running operation ole co
18. follows CALL 3E COMPANY 24 hours 1 800 451 8346 Toll free in the U S Canada and the U S Virgin Islands For calls originating elsewhere 760 602 8703 Collect calls are accepted The emergency response information services shown above have requested to be listed as providers of emergency response information and have agreed to provide emergency response information to all callers They maintain periodically updated lists of state and Federal radiation authorities who provide information and technical assistance on handling incidents involving radioactive materials Page 10 Service Manual Think A306 Page 27 of 32 Ener1 Lithium Power Systems 06 10001 rev 00 Rev Date 29 JAN 2011 5 MILITARY SHIPMENTS For assistance at incidents involving materials being shipped by for or to the Department of Defense DOD call one of the following numbers 24 hours 703 697 0218 call collect U S Army Operations Center for incidents involving explosives and ammunition 1 800 851 8061 toll free in the U S Defense Logistics Agency for incidents involving dangerous goods other than explosives and ammunition 6 NATIONWIDE POISON CONTROL CENTER United States Only Emergency and information calls are answered by the nearest Poison Center 24 hours 1 800 222 1222 toll free in the U S The above numbers are for emergencies only NATIONAL RESPONSE CENTER NRC The NRC which is operated by the U S Coast Guard recei
19. gnite other batteries in close proximity HEALTH Contact with battery electrolyte may be irritating to skin eyes and mucous membranes Fire will produce irritating corrosive and or toxic gases Burning batieries may produce toxic hydrogen fluoride gas see GUIDE 125 Fumes may cause dizziness or suffocation PUBLIC SAFETY CALL Emergency Response Telephone Number on Shipping Paper first If Shipping Paper not available or no answer refer to appropriate telephone number listed on the inside back cover Asanimmediaie precautionary measure isolate spill or leak area for at least 25 meters 75 feet in all directions Keep unauthorized personnel away Stay upwind Keep out of low areas Ventilate closed spaces before entering PROTECTIVE CLOTHING Wear positive pressure self contained breathing apparatus SCBA Structural firefighters protective clothing will only provide limited protection EVACUATION Large Spill Consider initial downwind evacuation for al least 100 meters 330 feet Fire Ifrail car or trailer is involved in a fire ISOLATE for 500 meters 1 3 mile in all directions also initiate evacuation including emergency responders for 500 meters 1 3 mile in all directions Service Manual Think A306 Page 29 of 32 Ener1 Lithium Power Systems 06 10001 rev 00 Rev Date 29 JAN 2011 ERG Guidelines for safet EMERGENCY RESPONSE FIRE Small Fire Dry chemical CO water
20. hite Yellow 3 Green 4 Orange Proof Test Voltage AC DC 2500 10 000 5 000 20 000 10 000 40 000 20 000 50 000 30 000 60 000 40 000 70 000 Max Use Rubber Voltage Molded Glove Label Rubber Dipped Ac DC Products Sleeve Label Label 500 750 A PS ene 10 me SE SALISBURY 7 5001 11 250 she a gh u ENSO984 CE0120 Maximum use DC voltage is not part of any ASTM specification Maximum use DC voltages are valid in reference to IEC 903 only Gloves and Sleeves must have a color coded label A Suitable for live working 10mM303 1E060903 2002 amp IE080417 fig 5216 VJ Fare ASTM Specification Reference D120 Rubber Insulating Gloves D178 Rubber Insulating Matting D1048 Rubber Insulating Blankets D1049 Rubber Insulating Covers D1050 Rubber Insulating Line Hose D1051 Rubber Insulating Sleeves In Service Care of Line Hose amp Covers In Service Care of Insulating Blankets In Service Care of Gloves amp Sleeves Leather Protectors for Insulating Gloves Inspection Guide for Rubber Products F479 F496 F696 F1236 Type l Designates natural rubber Type Il Designates SALCOR UV and ozone resistant rubber Service Manual Think A306 Page 11 of 32 Ener1 Lithium Power Systems 06 10001 rev 00 Rev Date 29 JAN 2011 3 4 Fire Extinguishers gt In the event of a fire associated with a battery pack Carbon Dioxide CO2
21. ies 4 cells in Cells per pack 384 parallel Refer to document 04 10004 for individual cell specifications Max Cell Voltage At 100 SOG State of Charge Min Cell Voltage At 0 SOC State of Charge C 3 rate used to determine capacity Refer to document 04 10004 for individual cell specification Rated Cell Capacity C 3 rate used to determine rated capacity Current Rated Pack Capacity BOL gt taper applied at the end of charge for determination of pack capacity Pack Capacity EOL 56 0 Ah 80 of rated pack capacity at BOL Open circuit voltage at 50 SOC State of Charge Nominal Pack Voltage a Refer to document 04 10004 for individual cell specification Rated Pack Energ 23 0 kWh C 3 rate at 25 C to determine rated energ Average Pack Energy 23 6 kWh C 3 rate at 25 C to determine average energy 2 2 Performance Specifications Max Continuous Discharge Power a s At 50 SOC State of Charge Max Continuous Charge Power paj oas 50 A at 50 SOC State of Charge repone E At50 SOC State of Charge for 30 Max Pulse Discharge Power seconds Maximum Discharge Current 4 Above 20 SOC State of Charge Max Charge Current While connected to charge plug Below 80 SOC State of Charge Maximum Regen Current while indiive mode Service Manual Think A306 Page 6 of 32 Ener1 Lithium Power Systems 06 10001 rev 00 Rev Date 29 JAN 2011 2 3 System Specifications Value JGondition 96 Series cel
22. ls Parallel cells DC impedance measured via Hybrid Pulse Power Internal pack resistance m Characterization HPPC 1 5C at 90 SOC State of Charge at 25 C Parameter Cell Configuration Internal cell temperature Recommended cell operating Operating Temperature C 25 to 55 temperature range is 28 C 36 Limited performance below 15 C and above 45 C Recommended storage Storage Temperature C 40 to 60 temperature is 25 C 5 Cat 40 to 60 SOC State of Charge kg 285 Approximate value See sec 6 0 Includes tray Approximate value See sec 6 0 2 4 A306 Pack Cover Removed 4 Lithium Power Systems Service Manual Think A306 Page 7 of 32 Ener1 Lithium Power Systems 06 10001 rev 00 Rev Date 29 JAN 2011 2 5 A306 installed in Vehicle Think City 4 Lithium Power Systems I ENERI Think City in the USA Service Manual Think A306 Page 8 of 32 Ener1 Lithium Power Systems 06 10001 rev 00 Rev Date 29 JAN 2011 Ener1 Battery installation Service Manual Think A306 Page 9 of 32 Ener1 Lithium Power Systems 06 10001 rev 00 Rev Date 29 JAN 2011 3 Battery Pack Safety WARNING 3 1 3 2 This system is to be operated solely in accordance with the supplied CAN bus user s guide Failure to do so will result in damage to the Pack System or Vehicle There are no user serviceable parts inside of pack case Pack safety systems are intended to protect the us
23. n battery pack Before working on a battery A Disconnect all 12 V connections U Disconnect all High Voltage connections Pack to Vehicle U Check for presence of electrolyte gt If strong solvent odor pack is compromised gt Do not investigate further without guidance from Eneri A Visual inspection should be made Service Manual Ener1 Lithium Power Systems Think A306 06 10001 rev 00 Page 10 of 32 Rev Date 29 JAN 2011 3 3 gt Paint surface discoloration gt Evidence of potential excessive heat or fire gt Remove all metal jewelry could cause a short A Hand jewelry OY Neck chains Q Be mindful of metal belt buckles gt Do not work on battery if you are the only one around U Use the buddy system gt High voltage output of the battery is potentially lethal gt Use extreme caution when making electrical connections or having any interaction with the battery gt PPE required QO Safety glasses Q Lineman s gloves 00 with leather overs check for perforations in gloves gt Perform Open Circuit Voltage OCV check using digital multimeter U Pack positive terminal to case U Pack negative terminal to case Q Readings should be zero gt If readings are something other than zero A Indication of internal short U Do not take any further steps without contacting Ener1 ASTM American Society for Testing and Materials Voltage Rating Chart Class Color 00 Beige Red W
24. nd date code of components and or software build to provide for serviceability and possible warranty reliability studies All field hardware and software service and installations must track all activity associated with each individual pack Any changes to a pack s configuration must be recorded and reported so that a pack s configuration matrix can be updated accordingly and in preparation for possible future support as required Service Manual Think A306 Page 15 of 32 Ener1 Lithium Power Systems 06 10001 rev 00 Rev Date 29 JAN 2011 4 3 3 Pack Interface Tools Recommended list of various tools to have kitted and on hand when supporting battery packs BOB Break out Box Harness Safety Glasses CAN Interface Cable 120 ohm termination Rubber Gloves Serial Cables Rubber Glove Protectors Banana Jack Jumpers Paint Marker permanent CAN interface box Scope meter DMM ELSI interface box Field Support Kit BOM Tool List 04282010 0001 4 3 4 Tool Ordering Information 4 3 5 Hand tools are mostly generic however specialty and custom proprietary pack interface hardware and software information is detailed below BOB Break out Box Harness hardware Desc Break out box with male male 15 ft cable assembly p n 1579102 Mfr CSI Electronics www csielectronics com Vendor CSI Electronics www csielectronics com CAN Interface Tool hardware and software Desc PCAN USB Adapter with optical isolation p n IPE
25. nk alte a 6 24 AZOGPRAOKP OTO LI ski A I a At la EEE a E es me aut A 6 2 5 A806 INSTALLED IN VEHICLE THINK CITY aa an nana nana anen nenen nenen eee e enen enen eee eee eter ete eter ete eter ete tee er eee eter tee eter eter 7 3 BATTERY PACK SAFE EN ci deves etic tt nadas 9 3 1 BATTERY PACK GERSON i Sht s es i sht 9 3 2 SAFETY GONSIDERATIONSe via sia s du aslohsss os dica st 9 3 3 ASTM VOLTAGE RATING CHART aaa aaa aaa aaa eee eee eee ese eee eke eke er eee eee eee nono eee pe eee tape ke ere eee eee ee ke ki ere teve eee vere er eseve 10 3 4 JFIRE EXTINGUISHERS oc e R 11 3 5 TRANSPORTER SAFETY INFORMATION c0cceececceeeeceeeeeecceececeueeeeeseeeeesuceaueeseseseeueuauausesseeeeeuseaueasaseeseeeeaeanens 11 4 BATTERY PACK SERVICE RESPONSE PLAN cccssssscceseseccccssssseseeueeseaeenssensesuseouansseseuuaeaeanansssesesuaeauans 12 4 1 POW CHART ck ta In stead Satan ia a ae A Tie renee Deus 13 42 STEP E GONTAGCT ENE RI ne 14 4 3 STEP 2 DEFINING AND ANALYZING A PROBLEM occccccccononocnccnnconononennnnnncnnnnononnanccnnnnnnnnnnnnanannncnnononnnncnaccnnnnnnos 14 4 3 1 DETAILED LOOK AT TOOLS AVAILABLE FOR ANALYSIS aa aaa aaa aaa eee eee eee ee ee de ES be See eke eke krere bebe eke vere ere eee eee 14 4 3 2 TRACEABIL Ve A PEE A il E E EP A PEATA EEA PTA EE 14 4 3 3 PACK INTERFACE K0 EAEE N A tt ti E TAEAE od di 15 4 3 4 TOOL ORDERING INFORMATION E E EEEE E E E EE EEE 15 4 3 5 SOFTIVARES RVICES en nia A A EAEE A
26. s basements or confined areas Do not direct water at spill or source of leak Use water spray to reduce vapors or divert vapor cloud drift Avoid allowing water runoff to contact spilled material Isolate area until gas has dispersed FIRST AID Move victim to fresh air Call 911 or emergency medical service Give artificial respiration if victim is not breathing Do not use mouth to mouth method if victim ingested or inhaled the substance give artificial respiration with the aid of a pocket mask equipped with a one way valve or other proper respiratory medical device Administer oxygen if breathing is difficult Remove and isolate contaminated clothing and shoes In case of contact with liquefied gas thaw frosted parts with lukewarm water In case of contact with substance immediately flush skin or eyes with running water for at least 20 minuies In case of contact with Hydrogen fluoride anhydrous UN1052 flush skin and eyes with water for 5 minutes then for skin exposures rub on a calcium jelly combination for eyes flush with a water calcium solution for 15 minutes Keep victim warm and quiet Keep victim under observation Effects of contact or inhalation may be delayed Ensure thai medical personnel are aware of the material s involved and take precautions to protect themselves Service Manual Think A306 Page 32 of 32 Ener1 Lithium Power Systems 06 10001 rev 00 Rev Date
27. s 06 10001 rev 00 Rev Date 29 JAN 2011 Ener1 Automotive Warranty Flow Nov 29 2010 T Reddington Customer notifies Ener1 of pack problem and sends diagnostic data n Kat a Fn a ae J Y AK Eneri provides a az A ic tech assistance as __ ner1 confirms failure via diag _ il Pi required via f no Ke data ee Level1 gt phone email hi m oe ae E dl AP lt Customer N resolves issue T yes Customer communicates Enerl issue is resolved and claim is cancelled Customer contacts Ener for further assistance no Eneri Technician ea dispatched to ge e dealer customer i lt location and pa Se cio performs Level 2 gt 2 repair SH yes Y Ener1 sends pack E Say from Service Is pack N ves Center to dealer lt replacement customer location N needed 7 Y TOE Ener1 dispatched Suspect components returned to to dealer Ener1 Service Center Ener1 conducts FA at Service Center l rada Failure confirmed via N _ analysis at pos p 9 cycling thermal 4 Ener1 yes Y Implement OP 10009 and OP 10010 Containment and Corrective and Preventative Action Procedure and Look across Claim verified Ener1 issues FS report updates lessons leamed and communicates dq to the customer Warranty database updated customer location and makes repairs n
28. solation Attach a 2 wire CAN Interface Cable from the PCAN USB Adapter to Vehicle CAN H and CAN L at the vehicle OBD On Board Diagnostic connector Start the re flash application software by running the Flash Tool executable v The application will start with preselected default options The default selections support MLEC programming CAN Rev Range is 61E 61F CAN KBaud is 500 and Auto mode v Select the Use CAN option Service Manual Think A306 Page 22 of 32 Ener1 Lithium Power Systems 06 10001 rev 00 Rev Date 29 JAN 2011 QO Click the Browse button and select the S19 file for the new MLEC Application Software Build to be programmed into the battery pack Example MLec_A306_25 s19 v Details for Begin End and Bytes of the S19 file will be displayed in the Reception Response window of the Flash Tool QI Turn Key Run ON to wake up the MLEC in the battery pack Q Click the Start button to begin re flashing of the new MLEC Application Software Build v Progress of re flash will be displayed in the Reception Response window of the Flash Tool v Ifthe re flash is completed successfully Flash operation complete will be displayed in the Reception Response window of the Flash Tool Q Turn Key Run OFF U Wait for six 6 seconds Q Turn Key Run ON to wake up the MLEC in the battery pack U Using a CAN diagnostic tool PCAN Viewer PCAN Explorer or other verify the contents o
29. spray or regular foam Large Fire Water spray fog or regular foam Move containers from fire area if you can do it without risk SPILL OR LEAK ELIMINATE all ignition sources no smoking flares sparks or flames in immediate area Do not touch or walk through spilled material Absorb with earth sand or other non combustible material Leaking batteries and contaminated absorbent material should be placed in metal containers FIRST AID Move victim to fresh air Call 911 or emergency medical service Give artificial respiration if victimis not breathing Administer oxygen if breathing is difficult Remove and isolate contaminated clothing and shoes In case of contact with substance immediately flush skin or eyes with running water for at least 20 minutes Ensure that medical personnel are aware of the material s involved and take precautions to protect themselves Service Manual Think A306 Ener1 Lithium Power Systems 06 10001 rev 00 Page 30 of 32 Rev Date 29 JAN 2011 6 2 1 3 Guide 125 Gases Corrosive ERG Guidelines for safety POTENTIAL HAZARDS EALTH TOXIC may be fatal if inhaled ingested or absorbed through skin Vapors are extremely irritating and corrosive Contact with gas or liquefied gas may cause burns severe injury and or frostbite Fire will produce irritating corrosive and or toxic gases Runoff from fire control may cause pollution IRE OR EXPLOSION Some
30. ssages gt Msg EDL_Active_Fault_Data CAN msg ID 721 gt Msg EDL_Latched_Fault_Data CAN msg ID 722 gt Msg EDL_History_Fault_Data CAN msg ID 723 gt For illustration purposes a copy of Malfunction Codes from Vehicle CAN Bus Guide associated with MLEC Application Software is shown below EDL_Active_Fault_Data CAN msg ID 721 EDL_Latched_Fault_Data CAN msg ID 722 Same bit definitions as active fault data EDL_History_Fault_Data CAN msg ID 723 Same bit definitions as active fault data Malf Name Byte 0 Bito 0 BUS VOLT AD FLT Bit1 1 PACK_VOLT_AD_FLT Bit2 2 PACK CUR B HI AD FLT Bit3 3 PACK_CUR_B_LO_AD_FLT Bit4 4 PACK_CUR_A_HI_AD_FLT Bit5 5 PACK CUR A LO AD FLT Bit6 6 BD_UNDER_TEMP_FLT Bit7 7 SEC_STUCK_ON_FLT Byte 1 Bito 8 INT_ISO_FLT Biti 9 EXT_ISO_FLT Bit2 10 SEC_CONTA_OPEN_FLT Bit3 11 CONT PCHG SHORT FLT Bit4 12 CONT1 DROPOUT 2ND FLT Bit5 13 CONT1_DROPOUT_1ST_FLT Bit 14 CONT_PCHG_RETRY_FLT Bit7 15 CONT_PCHG_FLT Byte 2 Bito 16 CONT2_RETRY_FLT Biti 17 CONT2_STUCK_ON_FLT Bit2 18 NO_CHARGE_CUR_FLT Bit3 19 BD_OVER_TEMP_FLT Bit4 20 UNDER_TEMP_FLT Bits 21 OVER_TEMP_FLT Bit6 22 FAN_CUR_LO_FLT Bit7 23 FAN_CUR_HI_FLT Byte 3 Bito 24 CONT1_RETRY_FLT Biti 25 CONT1_STUCK_ON_FLT Bit2 26 UNDER_VOLT_FLT_B Bit3 27 UNDER_VOLT_FLT_A Bit4 28 OVER_VOLT_FLT_B Bit5 29 OVER_VOLT_FLT_A Bit 30 OVER_CURRENT_FLT Bit7 31 SPI_FLT Byte 4 BitO 32 CONT2_DROPOUT_2ND_FLT Description Bus voltage A D fa
31. ult Pack voltage A D fault Pack current B hi A D fault Pack current B lo A D fault Pack current A hi A D fault Pack current A lo A D fault Circuit board under temperature fault A secondary contactor is stuck closed Internal isolation fault External or internal isolation fault Secondary contactor A or fuse A fault Short circuit detected at precharge Contactor 1 dropout second fault Contactor 1 dropout first fault Max number of precharge retries exceeded Contactor precharge timeout fault Max number of contactor 2 retries exceeded Contactor 2 detected stuck closed No charge current fault Circuit board over temperature fault Pack under low temperature fault Pack over temperature fault Fan current low open fault Fan current high fault Max number of contactor 1 retries exceeded Contactor 1 detected stuck closed Cell under voltage fault string B Cell under voltage fault string A Cell over voltage fault string B Cell over voltage fault string A Pack over current fault SPI transmit receive timeout fault Contactor 2 dropout second fault Page 20 of 32 29 JAN 2011 Service Manual Think A306 Page 21 of 32 Ener1 Lithium Power Systems 06 10001 rev 00 Rev Date 29 JAN 2011 Byte 5 Byte 6 Byte 7 Bit 1 33 CONT2_DROPOUT_1ST_FLT Contactor 2 dropout first fault Bit2 34 CONT1_STUCK_OPEN_FLT Contactor 1 detected stuck open Bit3 35 CONT2_STUCK_OPEN_FLT Contactor 2 detected stuck open Bit4 36 SEC_CON
32. ves reports required when dangerous goods and hazardous substances are spilled After receiving notification of an incident the NRC will immediately notify the appropriate Federal On Scene Coordinator and concerned Federal agencies Federal law requires that anyone who releases into the environment a reportable quantity of a hazardous substance including oil when water is or may be affected or a material identified as a marine pollutant must immediately notify the NRC When in doubt as to whether the amount released equals the required reporting levels for these materials the NRC should be notified CALL NRC 24 hours 1 800 424 8802 Toll free in the U S Canada and the U S Virgin Islands 202 267 2675 in the District of Columbia Calling the emergency response telephone number CHEMTREC CHEMTEL INC INFOTRAC or 3E COMPANY does not constitute compliance with regulatory requirements to call the NRC Page 11 Service Manual Think A306 Page 28 of 32 Ener1 Lithium Power Systems 06 10001 rev 00 Rev Date 29 JAN 2011 6 2 1 2 Guide 147 Lithium lon Batteries ERG Guidelines for safety POTENTIAL HAZARDS IRE OR EXPLOSION Lithium ion batteries contain flammable liquid electrolyte that may vent ignite and produce sparks when subjected to high temperatures gt 150 C 302 F when damaged or abused e g mechanical damage or electrical overcharging May burn rapidly with flare burning effect May i
33. y q q ENERI 8740 Hague Road Bldg 7 Indianapolis Indiana e 46256 e USA Think A306 Service Manual Document 06 10001 Ener1 Lithium Power Systems Service Manual Ener1 Lithium Power Systems Think A306 06 10001 rev 00 Rev Date Page 2 of 2 29 JAN 2011 Author Bill Hayes Date 29 JAN 12011 Service Manual Think A306 Page 1 of 32 Ener1 Lithium Power Systems 06 10001 rev 00 Rev Date 29 JAN 2011 Revision Record Revision Revision Change Description and Section s affected by the Level Date change o 2011 07 29 Service Manual Think A306 Page 2 of 32 Ener1 Lithium Power Systems 06 10001 rev 00 Rev Date 29 JAN 2011 TABLE OF CONTENTS T MANYA LOVER E Ao sddncanecaawadeauntadenacuedaceucs n ae d SHT ede 4 1 1 GENERAL PACK RATINGS SPECIFICATIONS aaa aa aaa aaa eee eee eee EP SEE SE eee te pe PERES Ee bebe eee EAn bebe eee teke k rere eee 4 1 2 BATTERY PACK SAFETY oeni e a a a E e ae aeaa aa a A ea A E aaa aeaa aE ea ieai 4 SUVA S KANOS VON 4 1 45 SERVICE RESPONSE PLAN Cauci n cala lana s M Sha ie shese ve batea cad 4 2 GENERAL PACK RATINGS 8 SPECIFICATIONS o ccccccooconconnoconconanananananconcnnananananrnnonnnnanananan cano SER S nana anna seen 5 2 1 RATED SPECIFICATION S kan n n ete a ti e I A 6 2 2 PERFORMANCE SPEGIFICATION S cuina u dt ar hd dt de h sot nest 6 2 34 SYSTEM SPECIEICATION S d nis an dat ce e td ta dh te ote
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