Bicker Elektronik BP-LFP-2725 User manual

User Manual BP-LFP-2725
BP-LFP-2725D
Bicker Elektronik GmbH
Ludwig-Auer-Straße 23 | 86609 Donauwörth | Germany
English

BP-LFP-2725(D)
Revision 1-2 2
Revision Directory
Legend of used symbols
Symbol Description
Attention! Important hazard warning.
Attention! Avertissement de danger important.
Do not dispose of in the domestic waste.
Ne pas jeter avec les ordures ménagères.
Warning of electrical voltage.
Avertissement de tension électrique.
Battery intended for recycling.
Batterie destinée au recyclage.
Date Change
05.01.2021
Revision 0-1
Initial version
07. 01. 2 021
Revision 1
Release version
14.04.2021
Revision 1-1
Chapter D: Backup time included
14.12.2021
Revision 1-2
Chapter D: Humidity included

BP-LFP-2725(D)
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BP-LFP-2725(D)
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A Features ................................................................................................................. 5
B Safety instructions ................................................................................................ 5
B1 General information...................................................................................................................................................5
B2 Safety instructions and warnings for battery use....................................................................................6
C Connections of battery system ............................................................................ 8
D Technical data........................................................................................................ 9
E Functionality of BMS .......................................................................................... 12
E1 Protection functions ............................................................................................................................................... 12
E2 Charging behaviour ................................................................................................................................................ 13
E3 Balancing........................................................................................................................................................................ 13
E4 Discharge ....................................................................................................................................................................... 13
E5 Deep discharge .......................................................................................................................................................... 14
E6 SMBus .............................................................................................................................................................................. 14
E7 Discharging process................................................................................................................................................ 14
E8 Charging process...................................................................................................................................................... 14
F Additional functions ........................................................................................... 15
G Operation modes................................................................................................. 15
G1 Switch position OFF................................................................................................................................................ 16
G2 Switch position UPSI............................................................................................................................................... 16
G3 Switch position ON (ONLY OPTIONAL)....................................................................................................... 17
H Assembly and installation advice (only for BP-LFP-2725D) ............................ 18
H1 Convection and installation position........................................................................................................... 18
H2 DIN-Rail mounting and DIN-Rail profile according to EN 60715................................................ 19
I Handling and storage instructions .................................................................... 20
J Transport instructions ........................................................................................ 20
K Disposal instructions........................................................................................... 21
L Other information .............................................................................................. 21

BP-LFP-2725(D)
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B Safety instructions
B1 General information
The safety instructions have to be read completely before the first use and carefully observed!
In addition, the corresponding safety data sheet has to be observed
.
Incorrect operation or connection may result in serious injury or death. Due to incorrect opera-
tion, leaving the limit values or incorrect connection risk of fire or explosion exists. When working
with the battery, care must be taken that no jewelry such as rings or watches are worn, which
can cause a short circuit.
A Features
BP-LFP-2725(D)
25.6 V DC / 2.5 Ah
 10-year long-life battery for challenging
applications
 High reliability and energy density
 Safe lithium-iron phosphate technology
 100% free of lead and cadmium
 Extended temperature range -20…+55 °C
 High performance battery management system
 Extended safety functions, charge algorithm
and cell balancing
 Integrated protection against deep discharge,
overcurrent, overvoltage, short circuit and
overcharging
 Compactly shrinked or as DIN-Rail version

BP-LFP-2725(D)
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The described limit values of the battery module must be observed. A violation of the limit
values can cause excessive heating, a defect in the battery module or fire.
As with other batteries, lithium batteries also have the potential to continue being a source of
danger even in the supposedly discharged state, as they can deliver a very high short-circuit
current.
Too deep discharge leads to lasting damage. Deeply discharged battery modules may no
longer be charged or operated. For example, deep discharge can occur during very long
storage of a battery module which was completely discharged (to discharge limit) when taken
into storage.
The battery must not be disassembled, opened, damaged or crushed.
The battery should not be exposed to heat or fire. Prolonged, direct sunlight is to be avoided.
The battery should be kept out of the reach of children.
The battery must not be short-circuited or connected with the wrong polarity.
The connection cables and plugs of the battery must not be modified.
One or more batteries should not be stored dangerously in a box or drawer where they could
short-circuit each other or be short-circuited by other conductive materials.
The battery must not be subjected to mechanical shocks.
Only use chargers specifically designed for use with lithium iron phosphate battery systems.
The polarity symbols plus (+) and minus (-) on the cells, batteries and devices must always be
observed. The correct use must be ensured.
The battery should be kept clean and dry.
If the battery connections become dirty, clean them with a dry, clean cloth.
The battery must be charged before use. The instructions of the manufacturer or the
information in these instructions for correct charging must always be observed.
B2 Safety instructions and warnings for battery use

BP-LFP-2725(D)
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If a cell leaks, the fluid must not come into contact with the skin or enter the eyes or mouth.
Measures in case of inhalation
Vapors or mists escaping from a damaged cell can cause respiratory irritation. When inhaling the
contents of an open cell, remove the source of contamination or remove the affected person to
fresh air. Seek medical help.
Measures in case of eye contact
Contact with the contents of an opened cell can cause severe burns or eye irritation. If eye contact
occurs with the contents of an opened cell, immediately rinse the contaminated eye(s) with a
lukewarm, slightly flowing stream of water for at least 30 minutes. Keep eyelids open. Neutral
saline may be used as soon as available. If necessary, further rinse the eyes during transport to the
emergency supply station. Take care that contaminated water is not flushed to the naked eye or
face. Immediately transfer the affected person to an emergency care center.
Measures in case of skin contact
Contact with the contents of an opened cell can cause burns. If skin contact occurs with the con-
tents of an open cell, remove contaminated clothing, shoes and leather parts. Rinse immediately
with lukewarm, low-flow water for at least 30 minutes. Seek medical attention if irritation symp-
toms or pain persist. Thoroughly wash or dispose of clothing, shoes and leather goods before
reuse.
Measures if swallowed
Contact with the contents of an opened cell can cause severe chemical burns to the mouth,
esophagus and gastrointestinal tract. If you swallow the contents of an open cell, DO NOT de-
liver anything by mouth if the subject becomes unconscious, unconscious, or has seizures. Rinse
mouth thoroughly with water. DO NOT INDUCE VOMITING. In case of spontaneous vomiting,
place the affected person in a forward bent position to reduce the risk of suffocation. Rinse mouth
again with water. Immediately transfer the affected person to an emergency care center.

BP-LFP-2725(D)
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C Connections of battery system
DATA CONNECTION COMMUNICATION
POWER SUPPLY
3x Red (Plus): AWG 18
3x Black (Minus): AWG 18
Cable length:
415 mm ±10 mm (Pack version)
315 mm ±10 mm (DIN-Rail version)
Plug: WST (WELISHENG TERMINAL)
P/N: P6-I42002
AWG 22
Cable length:
415 mm ±10 mm (Pack version)
315 mm ±10 mm (DIN-Rail version)
Plug: Würth Elektronik,
P/N: 624008213322
PIN
FUNCTION
1 N/A
2 SMBC
3 N/A
4 SMBD
5 N/A
6 SYSPRES
7 N/A
8 SGND
+
–
V+
V–
28
17

BP-LFP-2725(D)
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D Technical data
BP-LFP-2725(D)
ELECTRICAL DATA
Cell type A123 ANR26650-M1B
Nominal capacity 2.5 Ah
Nominal voltage 25.6 V
Energy 64 Wh
Voltage range Corepack 19.2 V…29.2 V
Overvoltage switch-o Once rst cell reaches 3.65 V
Overvoltage switch-o Recovery Once rst cell drops below 3.3V
Undervoltage switch-o Once rst cell reaches 2.4 V
Undervoltage switch-o Recovery As soon as all cells are over 3.1 V
Short-circuit switch-o ~64 A (200 µs)
Fuse 20 A
Own power consumption in energy-saving
mode 100 µA max.
Maximum installation height 5000 m
CHARGING PARAMETERS
Recommended end-of-charge voltage 27.6 V ±0.02 V
Charging mode CC/CV
Recommended charging current 1 C (2.5 A)
Maximum charge current 2.4 C (6 A)
Shutdown by BMS >6 A
Operating temperature range -20…+55 °C
Shutdown temperature range -30 °C (Recovery -25 °C)…+65 °C (Recovery +60 °C)
DISCHARGE PARAMETERS
End-of-discharge voltage ~19.2 V
Recommended discharge current 1 C (2.5 A)
Maximum discharge current 6 C (15 A)
Shutdown by BMS >18A ±2 A
Operating temperature range -20 °C…+55 °C
Shutdown temperature range -30 °C (Recovery -25 °C)…+75 °C (Recovery +70 °C)

BP-LFP-2725(D)
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MECHANICAL DATA
Dimension W / H / D Pack version: 108 x 63 x 70 mm ±0.5 mm
DIN-Rail version: 100 x 120 x 100 mm ±0.5 mm
(without rear DIN-Rail bracket)
Weight Pack version: 0.74 kg
DIN-Rail version: 1.00 kg
HUMIDITY
Operating 10…90 % RH, non-condensing
Storage 10…80 % RH, non-condensing
STORAGE
Recommended temperature range 25 °C ±5 °C
Maximum temperature range -25 °C…+55 °C
Recommended SoC 80 %
APPROVALS
UN38.3
IEC/EN IEC/EN62133-3
*Backup time depends on battery capacitance, load and temperature. At very high or low temperatures a reduction of backup time occurs.
Unless otherwise specified, the values apply to measurements at +25 °C.
0
20
40
60
80
100
120
140
160
180
200
220
240
260
280
300
10 20 30 40 50 60 70 80 90
100 110 120 130 140 150 160 170 180 190 200 210 220 230 240
Backup time* (in use with a UPSI-2412(D))
Backup time BP-LFP-2725
Backup time [min]
Pout W

BP-LFP-2725(D)
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MECHANICAL DIMENSIONS
Unless otherwise stated,
Tolerance according to:
DIN ISO 2768 T1 - m
DIN ISO 2768 T2 - K
BP-LFP-2725
415,00
108,00
70,00
63,00
BP-LFP-2725D
120,00
100,00
9,00
65,00
100,00
Unless otherwise stated,
Tolerance according to:
DIN ISO 2768 T1 - m
DIN ISO 2768 T2 - K

BP-LFP-2725(D)
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E Functionality of BMS
If the BMS is in ACTIVE MODE, diverse critical parameters of the battery system (such as voltages, currents, etc.)
are monitored cyclically by battery management system for compliance with the limits. In the event of a fault,
the battery system disconnects the main current path. Charging and discharging is only possible with an acti-
vated battery management system
E1 Protection functions
The BMS has several possibilities for detecting fault conditions. The following is a basic breakdown into short-
term, reversible and permanent errors:
If a short-term, reversible fault occurs during operation (e.g. overcurrent, overtemperature), the electronics will
switch off briefly and then switch on again when the fault no longer exists, otherwise the battery will remain
deactivated.
If a permanent fault occurs during operation (e.g. loss of a cell voltage tap, deep discharge), the battery remains
permanently deactivated and can only be re-enabled by the manufacturer (after troubleshooting).
Limits for short-term, reversible errors:
Short circuit and overload detection Over- and undervoltage detection
(cell)
First level of security Switch o by balancing IC
Second level of security 15 A fuse Thermic fuse
Abbreviation Description Limit values
CUV Cell undervoltage detection 2.4 V (Recovery 3.1V)
COV Cell overvoltage detection 3.65V (Recovery 3.3V)
OCD Overcurrent detection during discharging 18 A (50 ms)
ASCD Short-circuit detection during discharging ~64 A (200 µs)
OCC Overcurrent detection during charging 6 A (160 ms)
OTC Overtemperature detection of cells during charging +65 °C (Recovery +60 °C)
OTD Overtemperature detection of cells during
discharging +75 °C (Recovery +70 °C)
UTC Undertemperature detection of cells during charging –30 °C (Recovery –25 °C)
UTD Undertemperature detection of cells during
discharging –30 °C (Recovery –25 °C)

BP-LFP-2725(D)
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E2 Charging behaviour
The charging behaviour depends on the procedure described in chapter 'Charging process'. For this purpose,
a suitable charger should be used.
The charging process is finished when the current has dropped below the value of the Charge Term Taper
Current.
Charging an empty battery system
If a single cell falls below a voltage of 2.4 V, the discharge MOSFETs are blocked to prevent damage to the cells.
As soon as a charger is connected and its output voltage is active, the battery gets charged. The pin "System
Present" (F „Additional functions", page 15) of the communication plug must be switched to GND. If all cell
voltages exceed 3.1 V, the battery can be discharged again.
Note:
Under extreme conditions e.g. at particularly low or high temperatures, the charging and discharging be-
haviour in conjunction with your application should be checked. The cell characteristic leads to a different
voltage behaviour of the cells.
E3 Balancing
The BMS balances the cells during charging process. The necessary balancing times are automatically deter-
mined by the BMS.
E4 Discharge
The BMS switches off the output voltage when the final discharge voltage is reached. Protective functions of
temporary, reversible or permanent faults and short-circuit detection are not affected by this!
After complete discharge, charge the battery system soon (within 7 days) to avoid a deep discharge.
Abbreviation Description / Condition Comments
Charge Term Taper Current Current at end of charge Limit
Current <100 mA
CUV_RECOV_CHG
After discharge, the output voltage remains
de-activated until a loading process has taken
place.
Function is activated
Description Limits
Limit balancing ≥3.1V single cell voltage (during charging)
Balancing current ~100 mA (pulsed)

BP-LFP-2725(D)
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E5 Deep discharge
When the battery is not in use, the BMS switches to a power-saving mode with particularly low self-consump-
tion. Thereby the MOSFET main switch and various functions are turned off to protect the cells from deep
discharge.
PF shutdown voltage: If a cell voltage is below the limit(1.9 V) the BMS turns into a permanent error state. A
charging process is then no longer possible. The core pack is deeply discharged.
E6 SMBus
Various data of used balancer IC are available via SMBus. This is integrated into two-wire SMBus V1.1 standard.
E7 Discharging process
During discharge process, the pack voltage drops from the end-of-charge voltage (100 % SoC) to end-of-
discharge voltage (0 % SoC). Depending on current, the remaining capacity decreases continuously. If the
battery management system detects an error, it will be shut down as described in Section 'Functionality of BMS'.
E8 Charging process
Before using the charger for the first time, it is essential to read the operating instructions for the charger used!
General information
The charging process takes place according to the CC-CV procedure. After a charging phase with constant
current (CC, Constant Current) up to the end-of-charge voltage, the battery is charged with a constant voltage
(CV, Constant Voltage) and sinking current until the end of charge. Once the loading process has been success-
fully completed, pack-specific parameters (e.g. capacity etc.) are updated and the core pack is considered fully
loaded. If the battery management system detects an error, a shutdown occurs as described.

BP-LFP-2725(D)
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F Additional functions
System Present function
The use of this function is mandatory for the use of the battery. To enable the main current path, pin 6 (SP0)
must be bridged to pin 8 (GND) on the communication connector. Otherwise, the BMS permanently blocks the
main MOSFET switch.
Note:
In case of a failure, the MOSFET main switch is not enabled despite activated Syste Present function.
G Operation modes
The BP-LFP-2725 has a switch on the cable side of the pack near the cable outlets. This switch has three modes:
UPSI, UPSI, OFF. These different switch positions are printed on the label next to the switch:
Status PIN Behaviour battery
PIN 6 open load Main current path locked, charging and discharging of the battery is impossible
PIN 6 = PIN 8 = GND Main current path unlocked, charging and discharging of the battery possible
UPSI
UPSI
OFF

ON/OFF Switch

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G1 Switch position OFF
Please note: The following description applies to the BP-LFP-2725 (pack version), but not to the BP-LFP-2725D
(DIN rail version, see G2 "Switch position UPSI").
This is the switch position for long-term storage of the battery. The power consumption of the BMS is
reduced to an absolute minimum. The main switch of the BMS (Power-MOSFETs) is permanently blocked, which
means that the main power plug is de-energized. The battery cannot be charged or discharged in this switch
position. IC2communication with the battery is not possible.
Note that the battery should not be stored for a long time in a completely discharged state, as the BMS never-
theless has a very low power consumption and the batteries also show a certain self-discharge.
When the switch is in the OFF position, the storage life is approx. 1 year at 30 % SOC.
G2 Switch position UPSI
This is the switch position for operation with the UPS UPSI-2412 or UPSI-2412D from Bicker Elektronik GmbH.
BP-LFP-2725D : BP-LFP-2725D: In the DIN rail version of the battery the switch is delivered in the UPSI switch
position. It cannot be operated without opening the housing.
Both the communication plug and the main power cable must be connected to the UPS system. The UPSI-
2412(D) controls the connection and disconnection of the battery via the system present function of the 8-pin
communication connector. All necessary information is transferred to the UPSI-2412(D) via the SM bus: current
flow, individual cell voltages and state of charge. The protocol is based on the "Smart Battery Data Specification
v1.1".
Please note: After a complete backup operation of the UPSI-2412(D) together with the battery, it should be
recharged as soon as possible. If the input voltage returns to the UPS, it will automatically start charging the
battery.
If the UPS with connected discharged battery is not put in operation again for more than two weeks, the battery
may be deeply discharged.
IMPORTANT:
The switch position UPSI is available twice on the switch. The switch settings are the same in normal de-
livery. On request, the ON position can be activated by a jumper. The ON position allows the user to use
the battery without a Bicker UPS in the top switch position. In this position, various energy-saving modes
are forcibly inactive because the pack has to be always on standby. As this significantly increases the risk
of deep discharge in the event of accidental activation, this function is standardly deactivated.

BP-LFP-2725(D)
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G3 Switch position ON (ONLY OPTIONAL)
This switch position is used for operation without the Bicker UPS system, in the normal delivery state this is
deactivated and is only activated on customer request. The MOSFET main switch is always enabled (the system
present function is bridged). It is not necessary to use the communication connector for operation.
The function of the power button changes when activated as follows:
According to an 8S system with lithium iron phosphate batteries, the voltage at the main power plug can vary
between 19.2 V and 29.2 V depending on the state of charge. The battery can be discharged and charged accor-
ding to the given limit values.
Recommended end-of-charge-voltage: 27.6 V (=3.45 V per cell level)
Max. discharge current: 15 A
Max. charge current: 6 A
The maximum capacitive load, the battery can charge, is 1000 µF. Otherwise the battery detects a short circuit
and blocks the main current path.
IMPORTANT:
In switch position ON the battery is always on standby, so the BMS shows permanently the highest idle
consumption. The integrated power saving modes of UPSI operation are largely inactive. The battery
must not be stored in the ON switch position permanently. If a completely discharged battery is left in the
ON position, the battery will be deeply discharged within a few hours! It is recommended to recharge the
battery as soon as possible after discharge and to set it to the OFF position when not in use.
ON
UPSI
OFF

ON
UPSI
OFF

BP-LFP-2725(D)
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The devices comply with the IP protection class 20.
H Assembly and installation advice (only for BP-LFP-2725D)
H1 Convection and installation position
Do not cover any ventilation holes by adjacent components. For this DIN rail versions, vertical mounting on a
horizontal rail (DIN rails according to EN 60715) is recommended in order to achieve the best possible convec-
tion of the UPS. Another mounting position is possible, but operation up to the respective highest ambient
temperature can not be guaranteed.
The following distances to neighboring devices are recommended:
Left / right: 20 mm
Top / bottom: 50 mm

BP-LFP-2725(D)
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H2 DIN-Rail mounting and DIN-Rail profile according to EN 60715

2.

3.  4.

1.
Push down

BP-LFP-2725(D)
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J Transport instructions
The commercial transportation of lithium batteries is subject to the dangerous goods law.
Transport preparations and transport must only be carried out by appropriately trained persons
or the process must be accompanied by appropriate experts or qualified companies.
Transport regulations
Lithium batteries are subject to the following dangerous goods regulations and exceptions - in
the respective current version:
•
Class 9
• UN 3480: LITHIUM-ION BATTERIES (including lithium-ion polymer batteries)
• UN 3481: LITHIUM ION BATTERIES CONTAINED IN EQUIPMENT or LITHIUM ION BATTERIES
PACKED WITH EQUIPMENT
• Packing group: II
• Tunnel category E
Transport of damaged or defective battery modules
Defective or damaged battery modules are also subject to the stricter transport special provision
376. These reach all the way to packaging in an aluminum box with vermiculite filling or a com-
plete transport ban.
Air transport of waste batteries
Waste batteries and batteries transported for purposes of recycling or disposal are excluded from
air freight unless authorized by the competent national authorities of the country of origin and
the country of the executing company. (IATA DGR SP A183)
The battery has to be protected immediately after disconnection from UPSI-2412(D) or the
application. No foreign particles (e.g. metal splinters, small nails, chips or other conductive
metals) should enter the battery.
The battery should not be exposed to moisture (water, rain water, snow, etc.) during storage.
To avoid deep discharge, the battery should be charged before storing and checked at least
every 2 months. If necessary, the battery is to be charged to 80 %.
The battery should be stored in a cool and dry place where it is protected from damage and
unauthorized access.
High temperature uctuations in the storage area should be avoided, for example storage next
to heaters. Do not expose battery modules permanently to solar radiation.
To achieve optimum battery life, it should be stored at a temperature of +25°C ±5 °C and a
humidity of 10 % to 80%. The state of charge should be more than 30 %, ideally 80 %.
When the battery is completely discharged, the battery must be charged as soon as possible.
I Handling and storage instructions