Aentron A12020M User manual

Lithium-ion Battery
2 kWh - 12 V DC / 24 V DC / 48 V DC
Type M
Type R
A12
020M
A24020M
A48020M
A12020R
A24020R
A48020R
Version 1.3
Operating Manual
English
English

Table of Contents
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Version 1.03
Table of Contents
1. Introduction .............................................................................. 4
1.1. General ............................................................................................... 4
1.2. Terminology ....................................................................................... 5
1.3. Explanation of Symbols ................................................................... 5
1.3.1. Structure of the Safety Instructions ............................................. 5
1.3.2. Symbols, Warning Signs and Mandatory Signs .......................... 6
1.3.3. Abbreviations ..................................................................................... 7
1.4. Labelling ............................................................................................. 8
1.5. Contact Address ............................................................................... 9
2. About the aentron Lithium-ion Battery .............................. 10
2.1. Using the Lithium-ion Battery .................................................... 10
2.1.1. Intended Use .................................................................................. 10
2.1.2. Foreseeable Misuse ...................................................................... 11
2.2. Technical Data ............................................................................... 11
2.2.1. Dimensions ..................................................................................... 11
2.2.2. Electrical Specification ................................................................. 12
2.2.3. Additional Specifications ............................................................. 13
2.2.4. Ambient Conditions ....................................................................... 13
2.2.5. Standby Current Consumption ................................................... 14
2.3. Scope of Delivery ........................................................................... 15
2.3.1. Versions of the Lithium-ion Battery .......................................... 15
3. Safety ...................................................................................... 16
3.1. Basic Functional Safety................................................................ 16
3.2. Warnings of a General Nature .................................................... 17
3.3. Thermal Hazards............................................................................ 18
3.4. Electrical Hazards .......................................................................... 18
3.5. Dangers Caused by Materials and Substances ...................... 19
3.6. Safety Equipment .......................................................................... 19
4. Preparation for Use ............................................................... 20
4.1. Layout and Controls ...................................................................... 20
4.1.1. LED Definition ................................................................................ 21
4.2. Interfaces External Systems ........................................................ 22
4.3. Transport and Storage .................................................................. 24
4.3.1. Unpacking ....................................................................................... 25
4.4. Installation ...................................................................................... 25
4.4.1. Installation Location of the Lithium-ion Battery ..................... 25
4.4.2. Electrical Connection .................................................................... 26
4.4.3. Connections CAN Bus (only Type R) ......................................... 27

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4.4.4. Checking the Functions ................................................................ 28
4.5. Commissioning ............................................................................... 28
5. Operation the Lithium-ion Battery ...................................... 29
5.1. General ............................................................................................ 29
5.2. Modes of Operation ...................................................................... 29
5.2.1. Parallel Connection ....................................................................... 30
5.3. Normal Operation .......................................................................... 31
5.3.1. Starting as a Stand-Alone Solution ........................................... 31
5.3.2. Charging .......................................................................................... 32
5.3.3. Charging Method ........................................................................... 33
5.3.4. Charge Equalisation ...................................................................... 33
5.3.5. Saving Power .................................................................................. 33
6. Maintenance ........................................................................... 34
6.1. Operational and maintenance standards for lithium-ion
batteries........................................................................................... 34
6.2. Avoidance of deep discharge ...................................................... 34
6.3. Operational life time ..................................................................... 35
6.4. Cycle life-time ................................................................................ 36
6.5. Service and repair .......................................................................... 36
6.5.1. Packaging ........................................................................................ 36
6.5.2. Dangerous good labels on the transport box ........................... 37
6.5.3. Transport service provider ........................................................... 38
7. Cleaning, Maintenance and Care ........................................ 39
7.1. Cleaning and Care ......................................................................... 39
7.2. Maintenance ................................................................................... 39
8. Decommissioning and Disposal .......................................... 40
8.1. Decommissioning .......................................................................... 40
8.2. Storage ............................................................................................. 41
8.3. Winter Storage ............................................................................... 42
8.4. Disposal and Recycling ................................................................ 42
9. Faults and Notifications ....................................................... 43
9.1. Troubleshooting ............................................................................. 43
9.2. Emergencies ................................................................................... 45
9.3. Frequently Asked Questions (FAQ) ........................................... 45
10. Legal Information .................................................................. 48
10.1. Warranty Conditions ..................................................................... 48
10.2. Copyright and Property Rights .................................................... 48
10.3. Material and Legal Defects ......................................................... 49
10.4. Approvals and EU Declaration of Conformity .......................... 49

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10.5. EMC .................................................................................................. 51
11. Plans ........................................................................................ 52
11.1. Maintenance plan .......................................................................... 52
11.2. Maintenance Protocol .................................................................. 53

Introduction
General
aentron GmbH Lithium-ion Battery Page 4/59
Version 1.03
1. Introduction
1.1. General
This operating manual enables the safe and efficient handling of the
aentron lithium-ion battery and describes all the essential functions.
This operating manual ensures the safe operation of the lithium-ion battery
in accordance with the intended use.
This document contains:
■ Description of the design, functions and features of the lithium-ion
battery
■ Notes on possible dangers, their consequences and on measures for
hazard prevention
■ Detailed specifications on the standard operation of the lithium-ion
battery.
The operating manual must be stored away safely for users to be able to
access at any time. Please read the operating manual carefully before placing
the lithium-ion battery into operation.
For the safe and efficient use, all the safety instructions and handling
instructions of this operating manual must be read and understood.
Furthermore, we recommend following the requirements of
EN ISO 16315:2016 for the integration and professional installation of the
lithium-ion battery.
In this operating manual, the latest version of the lithium-ion battery is
described. If changes or supplements are required in the future, the operating
manual is amended, and all amendment are included in the next revision.
The respective version of the operating manual is displayed on the cover
sheet and in the footer; this operating manual is version "1.0". The version
will be increased by "1" with every revision.
aentron GmbH reserves the right to make changes to systems and
documentation without notifying users of previous versions.
TIP
If the lithium-ion battery is passed or sold on to third parties, the
following documents must be passed on to the new user:
 This operating manual
 Documentation of repair work carried out.

Introduction
Terminology
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Version 1.03
1.2. Terminology
Cell
The cell is the smallest part of an electrochemical storage system and stores
the chemical energy.
Module
A grouping of multiple cells or cell blocks, fitted with a battery management
system.
Battery
A battery refers to when several modules are connected in parallel or in
series.
Battery system
If several modules are connected in parallel or in series and are managed by
an energy controller, this is referred to as a battery system.
1.3. Explanation of Symbols
1.3.1. Structure of the Safety Instructions
The safety instructions in this document are presented with a standardised
format and symbols. Depending on the probability of occurrence and the
severity of the consequences, the following hazard classes are used:
WARNING
Indicates a hazardous situation which could lead to serious
physical injury or burns.
 Measures for preventing the hazard
NOTICE
Indicates a situation that could lead to property damage.
 Measure for preventing the property damage
TIP
Application tips and particularly useful information

Introduction
Explanation of Symbols
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1.3.2. Symbols, Warning Signs and Mandatory Signs
Warning of a hazard point
Warning of electrical voltage
Warning of corrosive substances
Warning of a fire hazard
Application tips and other useful information
Symbols on the Lithium-ion Battery
Pay attention to the manual
Not for disposal with domestic waste
CE mark
ECE R10 mark
UN38.3 mark

Introduction
Explanation of Symbols
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Version 1.03
1.3.3. Abbreviations
■ E-Switch = Electronic switch
■ C-Rate = Current to charge the battery in 1 hour
■ SoC = State of Charge of the Battery
■ DoD = Depth of Discharge
■ BMS = Battery Management System
■ BLK = Black
■ CAN = Controller Area Network / Serial Bus System
■ GND = Chassis Ground
■ CCCV = Constant Current, Constant Voltage

Introduction
Labelling
aentron GmbH Lithium-ion Battery Page 8/59
Version 1.03
1.4. Labelling
Every lithium-ion battery from aentron GmbH is fitted with a type plate. This
is located on the front / top of the lithium-ion battery.
1
Type name
2
V
oltage, Capacity, Energy
3
Safe operating voltage, operating t
emperature
4
Serial number
5
Part number
6
CAN node ID number
7
Production date
8
Serial number
9
Contact information
Figure 1: Type Plate M-Type (example)

Introduction
Contact Address
Page 9/59 Lithium-ion Battery aentron GmbH
Version 1.03
Figure 2: Type plate R-Type (example)
1
Type name
2
Voltage, Capacity, Energy
3
Safe operating voltage, operating t
emperature
4
Serial number
5
Part number
6
CAN node ID number for 01T = Terminator (only for type R)
7
Production date
8
Serial number
9
Contact informati
on
1.5. Contact Address
aentron GmbH - Energy Solutions
Dornierstraße 21
82205 Gilching
GERMANY
Phone: [phone]
Fax: [phone]
www.aentron.com
[e-mail]

About the aentron Lithium-ion Battery
Using the Lithium-ion Battery
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Version 1.03
2. About the aentron Lithium-ion Battery
2.1. Using the Lithium-ion Battery
The aentron lithium-ion battery has been designed so that it can be used as
a modular assembly, either as a single device or in a parallel configuration
with other appropriate lithium-ion batteries of the same capacity and power
of up to 60 V.
The modular concept of the lithium-ion batteries enables scalable
configurations of up to a maximum of 4 modules in parallel of up to 60 Vdc,
without a higher-level control system being required. The lithium-ion
batteries in conjunction with our integrated Battery Management
System (BMS) are therefore designed and configured for high performance
and safe operation.
All lithium-ion batteries have galvanic isolation to ground > 1,000 Vdc.
Thanks to the integrated BMS, all safety-related parameters of the lithium-
ion battery - such as over / undervoltage, over-current, over / under
temperature, cable breaks and charge level - are continuously monitored.
2.1.1. Intended Use
The lithium-ion battery is equipped with the latest Li-NMC cell technology
and is designed for the following applications:
■ E-Industry
■ E-Maritime
■ E-Mobility
■ ON / OFF grid
The lithium-ion battery can be operated as a stand-alone solution or used in
a parallel connection with a maximum of 4 x lithium-ion batteries. Should you
require greater capacities, please contact your authorised aentron dealer.
The limits to use described in this user manual must always be complied
with.
The lithium-ion battery must only be used for purposes described in this user
manual.

About the aentron Lithium-ion Battery
Technical Data
Page 11/59 Lithium-ion Battery aentron GmbH
Version 1.03
2.1.2. Foreseeable Misuse
Use of the lithium-ion battery other than or in addition to that described in
chapter 2.1.1. Intended Use is considered to be improper use, meaning
incorrect use, and this leads to warranty invalidation.
This applies in particular to the use of the lithium-ion battery for applications
in medical or aerospace industries.
2.2. Technical Data
The conditions at the location of usage of the lithium-ion battery must match
the conditions which are presented as permissible ambient conditions in this
operating manual.
aentron GmbH assumes no liability for damage arising from use in different
conditions.
2.2.1. Dimensions
Figure 3: Dimensions lithium-ion battery 2 kWh

About the aentron Lithium-ion Battery
Technical Data
aentron GmbH Lithium-ion Battery Page 12/59
Version 1.03
12 Vdc / 24 Vdc / 48 Vdc - 2 kWh Li-ion
Type M (60 A), Type R (200 A)
Length [mm] 442,5
Width [mm] 310
Depth [mm] 115
Weight [kg] approx. 22
2.2.2. Electrical Specification
12 Vdc / 24 Vdc / 48 Vdc
2 kWh Li-ion Type M (60 A) 12 Vdc / 24 Vdc / 48 Vdc 2 kWh Li-ion Type R (200 A)
Nominal
voltage [Vdc] 12 / 24 / 48 12 / 24 / 48
Operating
voltage [Vdc] 12 to 16 / 21 to 28 / 42 to 56 12 to 16 / 21 to 28 / 42 to 56
aentron ID A12020M / A24020M / A48020M A12020R / A24020R /
A48020R
Capacity [Ah] 140 / 80 / 40 140 / 80 / 40
Power [Wh] 2000 2000
Continuous
current [A] 60 200
Control system E-Switch, status LED E-Switch, CAN bus, status
LED

About the aentron Lithium-ion Battery
Technical Data
Page 13/59 Lithium-ion Battery aentron GmbH
Version 1.03
2.2.3. Additional Specifications
12 Vdc / 24 Vdc / 48 Vdc - 2 kWh Li-ion
Type M (60 A), Type R (200 A)
Configuration Max.: 60 V / 4 x parallel (8 kWh)
Technology Li-NiCoMnO2
Cell balance Passive (150 mA)
Cooling concept Passive
Approvals UN 38.3, CE, RoHS, DNV-GL
Cycles (full) approx. 3,000 (80 % Kp @ +20 °C)
Fast charging 0.5 - 2 C
Housing material Aluminium die casting
Feed terminal RADLOK 10 mm (RED & BLK)
2.2.4. Ambient Conditions
Recommended operating
temperature range [°C] 0 to +30
Max. component standby
temperature [°C] +80
Min. operating temperature [°C] -20
Max. operating temperature [°C] +60
Charging temperature range [°C] +0 to +50
Relative humidity [%] 5 - 95
Transport / delivery conditions -20 °C to +30 °C at 65 % ambient humidity
Ingress protection (IP) class IP66
UL flammability class UL94 V0
Operating height [m] < 4,000

About the aentron Lithium-ion Battery
Technical Data
aentron GmbH Lithium-ion Battery Page 14/59
Version 1.03
2.2.5. Standby Current Consumption
Type M - Standby current consumption until the lithium-ion battery
switches to deep-discharge protection
2 kWh Li-ion - Type M,
standby status Load (W)
SoC (%) 12 Vdc / 24 Vdc / 48 Vdc
Time until deep discharge
E-Switch ON 0.05 100 40,000 hours / 1,666 days
E-Switch ON 0.05 50 20,000 hours / 833 days
E-Switch ON 0.05 5 2,000 hours / 83 days
E-Switch ON 0.05 1 400 hours / 16 days
Type R - Standby current consumption until deep-discharge protection is
initiated by the lithium-ion battery
2 kWh Li-ion - Type R,
standby status Load (W)
SoC (%) 12 Vdc / 24 Vdc / 48 Vdc
Time until deep discharge
E-Switch ON & RELAY CLOSED 4.6 100 420 hours / 17 days
E-Switch ON & RELAY CLOSED 4.6 50 210 hours / 8 days
E-Switch ON & RELAY CLOSED 4.6 5 20 hours
E-Switch ON & RELAY CLOSED 4.6 1 4 hours
2 kWh Li-ion - Type R,
standby status Load (W)
SoC (%) 12 Vdc / 24 Vdc / 48 Vdc
Time until deep discharge
E-Switch ON & RELAY OPEN 2.8 100 710 hours / 29 days
E-Switch ON & RELAY OPEN 2.8 50 355 hours / 14 days
E-Switch ON & RELAY OPEN 2.8 5 35 hours
E-Switch ON & RELAY OPEN 2.8 1 7 hours
2 kWh Li-ion - Type R,
standby status Load (W)
SoC (%) 12 Vdc / 24 Vdc / 48 Vdc
Time until deep discharge
System OFF 0.05 100 40,000 hours / 1,666 days
System OFF 0.05 50 20,000 hours / 833 days
System OFF 0.05 5 2,000 hours / 83 days
System OFF 0.05 1 400 hours / 16 days

About the aentron Lithium-ion Battery
Scope of Delivery
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Version 1.03
2.3. Scope of Delivery
2 kWh - Type M and R 12 V, 24 V, 48 V
1
Energy storage system
2
4 x cover mounting holes (M6 x 20 mm)
4 x base mounting holes
(M8 x 30 mm)
3
Mounting rail set*
4
4 x fixing screws (M
8
x
16
m
m) for horizontal rails*
5
4 x fixing screws (M
6
x 1
0
mm) for support rails*
6
4 x fixing screws (M6 x
25
mm) for cover rails*
7
(+) / (
-
) Power connection sockets (10 mm)
8
Communications cable (8
-
pin)*
* Optional - Available separately and dependent on the configuration
2.3.1. Versions of the Lithium-ion Battery
Type M - 2 kWh Type R - 2 kWh
■ A12020M - 12 V - 2 kWh
■ A24020M - 24 V - 2 kWh
■
A48020M
-
48
V
-
2
kWh
■ A12020R - 12 V - 2 kWh
■ A24020R - 24 V - 2 kWh
■
A48020R
-
48
V
-
2
kWh
Equipment options:
■ Integrated ON / OFF E-Switch or remote switch (remote control)
■
CAN bus (only for Type R)
You can find the technical specifications of the individual versions in chapter
2.2. Technical Data.
Figure 4: Scope of delivery (2 kWh - Type M and R)

Safety
Basic Functional Safety
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3. Safety
You can find a detailed explanation of the safety and warning symbols in
chapter 1.3. Explanation of Symbols.
Special safety regulations may apply to particular activities. Safety and
warning signs for such activities can be found in the respective chapters of
this operating manual.
3.1. Basic Functional Safety
For the operation of the lithium-ion battery, safety, accident prevention and
environmental protection regulations must also be followed.
Only use the lithium-ion battery:
■ For its intended purpose, in a safe and hazard-conscious manner and by
paying attention to this operating manual.
■ If all safety equipment is present and fully functional.
■ If the lithium-ion battery is in a technically flawless condition.
This also includes:
■ The warning signs and labels attached on the lithium-ion battery must
always be complete and in a legible condition. Replace damaged or
illegible signs. Please refer to your authorised aentron dealer.
■ Only perform installation, cleaning and / or disassembly work when the
lithium-ion battery is switched off.
NOTICE
Physical damage to the lithium-ion battery due to excessive current
flow through voltage compensation.
 Prior to connecting in parallel, measure the respective voltage of the
individual lithium-ion batteries.
Make sure that the voltages between the individual lithium-ion
batteries DO NOT deviate > 1 Vdc.

Safety
Warnings of a General Nature
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Version 1.03
3.2. Warnings of a General Nature
■ ONLY take the lithium-ion battery out of the original packaging if it is
required for use.
■ DO NOT subject the lithium-ion battery to any excessive mechanical
shocks; e.g. from dropping.
■ DO NOT remove the attached handles which are required for preventing
accidental drop damage.
■ The pressure-equalisation membrane must NOT be blocked or covered.
The lithium-ion battery does not need any extra ventilation under normal
operating conditions.
■ In addition, you should fit your application with an electric fuse which is
rated lower than the fuse of the lithium-ion battery (e.g. 10 % to 20 %
lower). Please note the technical data of the lithium-ion battery in this
regard.
Type M fuse: 63 A; Type R fuse: 200 A
■ If the internal fuse of the lithium-ion battery fails, please refer to your
authorised aentron dealer for support and repairs.
DO NOT attempt to replace the fuse, otherwise the warranty for the
lithium-ion battery will be invalidated.
■ ONLY use chargers which have been authorised by aentron GmbH.
■ Ensure correct polarity when connecting the lithium-ion battery and the
charger.
■ DO NOT combine or mix different manufacturers, capacities, sizes or
types of other battery technologies with the lithium-ion battery.
■ ONLY use the lithium-ion battery for the intended application and power;
see chapters 2.1.1. Intended Use and 2.2. Technical Data.
■ Ensure that the voltages between the individual lithium-ion batteries
DO NOT deviate > 1 Vdc for every parallel connection.
■ The lithium-ion battery boasts IP protection class 66, and is thus splash-
proof. It should, however, not be subjected to wet conditions
continuously for its own protection.
■ NEVER use a damaged Lithium module.
■ When handling and mainteaning the Li-ion module use suitable test
devices and personal safety clothing, safety gloves and protective
eyewear.
■ Remove and Store the Lithium module electrically separated and isolate
the (+)/ (-) battery pole. Pay attention that there are still some voltage
on the DC-outputs when the battery module is inactive (OFF).
■ Switch the lithium-ion battery off when not in use.

Safety
Thermal Hazards
aentron GmbH Lithium-ion Battery Page 18/59
Version 1.03
■ Store away the original packaging for servicing / repairs / disposal at the
end of the service life.
3.3. Thermal Hazards
Risk of fire possible due to overheating of the lithium-ion battery.
 DO NOT subject the lithium-ion battery to any excessive heat or
fire (> +60 °C).
 Pay attention to the safety instructions attached to the lithium-ion
battery.
DO NOT exceed the permissible temperature
ranges; see chapter 0.
 Ambient Conditions.
 DO NOT leave the lithium-ion battery switched on with exposed
terminals. This could lead to a short circuit.
 In the event of a fire, use a CO2 fire extinguisher or a fire
extinguisher with non-conductive foam. Please proceed as
follows:
 Step 1: Extinguish with CO2 fire extinguisher / fire
extinguisher with non-conductive foam
 Step 2: Cool with CO2 fire extinguisher / fire extinguisher
with non-conductive foam
 Step 3: Isolate -> Place the lithium-ion battery in a secure
location for at least seven days and also cover it with
sand.
 Remove the lithium-ion battery in the event of a short circuit or
overcharge and isolate it for 24 - 48 hours to prevent internal cell
short circuit (slow-burn short circuit). Refer to your authorised
aentron dealer immediately for further assistance.
3.4. Electrical Hazards
Fatal electric shock possible due to improper handling of the
lithium-ion battery.
 DO NOT attempt to open, repair or disassemble the lithium-ion
battery.
 Repairs must only be performed by specialist personnel
authorised by aentron GmbH.

Safety
Dangers Caused by Materials and Substances
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3.5. Dangers Caused by Materials and Substances
Risk of corrosion possible due to the lithium-ion battery leaking.
 In the event of the lithium-ion battery leaking, the fluid must not
come into contact with the skin or the eyes.
 In the event of contact, rinse the affected area with plenty of water
and seek medical attention.
3.6. Safety Equipment
BMS - Battery Management System
Thanks to the integrated BMS, all safety-related parameters of the lithium-
ion battery - such as over / undervoltage, over-current, over / under
temperature, cable breaks and charge level - are continuously monitored.
Battery Heating System (only for Type R)
For operation at low temperatures below -10 °C, the lithium-ion batteries
can optionally be fitted with an internal heating system.
This function is only available for the lithium-ion battery Type R.
Please refer to your authorised aentron dealer for more information.