Cegasa eBick MCP Series User manual

USER MANUAL
-FIRST STEPS -

www.cegasa.com

www.cegasa.com
www.cegasa.com Page -1- User Manual R10 –First steps –
Revision control
REV.
DATE
REASON / RESPONSIBLE
00
01/08/2018
First issue
01
09/10/2018
R&D
02
31/10/2018
R&D
03
29/11/2018
R&D
04
30/11/2018
R&D
05
25/01/2019
Changed CAN connector pin-out
06
11/02/2019
Revision IV
07
13/02/2019
Revision IV
Limitation of Warranty and Liability
The limitation of warranties and liabilities shall be described in the contractual
agreements between CEGASA ENERGIA and the buyer.
The information included in this manual has been written for the purpose of providing the
user with more detail and clarity in terms of content. Nonetheless, CEGASA ENERGIA
reserves the right to modify the contents of this manual through future revisions at any
time and without prior notice.
Confidentiality
All information provided by CEGASA ENERGIA by virtue of this User Manual and any
data or features that may be disclosed by such shall be completely confidential and may
not be shared with third parties or used for purposes other than that for which is was
intended without prior and express written authorization from CEGASA ENERGIA.
Limitations on the use of this equipment
This equipment may not be used in applications for recharging electric vehicles.
CEGASA ENERGIA shall not be held liable for use with these types of application. The
buyer shall be wholly responsible.
Contact
CeGASA ENERGIA
C/Marie Curie, 1
Parque tecnológico de Álava,
01510 Miñano (Vitoria-Gasteiz)-España
Tel. [phone]
www.cegasa.es

www.cegasa.com
www.cegasa.com Page -2- User Manual R10 –First steps –
Contents
1 Introduction .......................................................................................................................... 4
1.1 Purpose ......................................................................................................................... 4
1.2 Acronyms....................................................................................................................... 4
2 Technical characteristics of eBick system ............................................................................. 5
3 Safety..................................................................................................................................... 6
3.1 Symbols ......................................................................................................................... 6
3.2 General information...................................................................................................... 7
3.3 Safety instructions –Potential hazards......................................................................... 7
3.5 Electrical safety ............................................................................................................. 8
3.6 Mechanical safety ......................................................................................................... 8
3.7 User requirements ........................................................................................................ 8
3.8 Lockout-tagout of machines and installations (LOTO).................................................. 9
3.9 Switching, measurements and checks .......................................................................... 9
4 Assembly of the equipment ................................................................................................ 10
4.1 Potential hazards......................................................................................................... 11
4.2 Initial check ................................................................................................................. 11
4.3 Fitting the modules ..................................................................................................... 12
5 Commissioning the equipment ........................................................................................... 18
5.1 System start-up and shut-down processes................................................................. 18
5.2 Power connection process.......................................................................................... 18
5.3 Pre-charge process (only in stand-alone mode) ......................................................... 19
5.4 ID Configuration (Only if necessary)............................................................................ 19
5.5 Current calibration (Only if necessary) ....................................................................... 25
6 Data display......................................................................................................................... 27
6.1 Change of language..................................................................................................... 27
6.2 HMI display.................................................................................................................. 27
6.3 Change system date and time..................................................................................... 31
7 Communications ................................................................................................................. 35
7.1 Introduction ................................................................................................................ 35
7.2 CAN protocol............................................................................................................... 35
7.3 Modbus protocol......................................................................................................... 35
7.4 CAN object dictionary & Modbus map........................................................................ 35
7.5 Configuration with VICTRON ENERGY equipment ...................................................... 35

www.cegasa.com
www.cegasa.com Page -3- User Manual R10 –First steps –
8 Working with the eBick ....................................................................................................... 36
8.1 Precharge .................................................................................................................... 36
8.2 Charging ...................................................................................................................... 36
8.2.1 MCP Series........................................................................................................... 36
8.2.2 MCP Parallels....................................................................................................... 37
8.3 Discharging.................................................................................................................. 37
8.4 Equalizing .................................................................................................................... 37
8.5 SOC Algorithm ............................................................................................................. 38
8.6 Alarm reset.................................................................................................................. 38
8.7 Ultra-consumption mode............................................................................................ 39
9 Environmental operating conditions................................................................................... 39
10 Maintenance and storage procedure.............................................................................. 39
11 Transport rules................................................................................................................ 40
12 Product warranty ............................................................................................................ 40

www.cegasa.com
www.cegasa.com Page -4- User Manual R10 –First steps –
1 Introduction
1.1 Purpose
The following document presents the first steps to ensure that the eBicks are installed
and used safely. The companyrecommendsreading the whole usermanual beforehand,
which can be downloaded from the website or requested in electronic format from the
company supplying the equipment
1.2 Acronyms
FAT
Factory Acceptance Tests
BMS
Battery management system
eBick
Battery pack 48V
GBMS
Global battery management system
MCP
Control and protections module
SOC
State of charge.
SOF
State of function. Maximum amount of current
permissible loading or unloading at any time

www.cegasa.com
www.cegasa.com Page -5- User Manual R10 –First steps –
2 Technical characteristics of eBick system
Module MCP (Control and protections)
MCP SERIEs
MCP PARALLELs
Chemistry
LiFePO4 (LFP)
LiFePO4 (LFP)
Rated voltage [V]
Depending on the number
of modules connected in
series
(consult CEGASA)
48
Voltage range [V]
41 - 52,5
Capacity [Ah]
180
Depending on the
number of modules
connected
Energy [KWh]
Depending on the number of modules connected
I MAX charge continuous [A]
180
250
I MAX discharge continuous [A]
180
250
I MAX discharge pulse (seg.) [A]
360 (15seg)
360 (30seg)
Rated power continuous [KW]
Depending on the number
of modules connected in
series
12KW
Rated power pulse [KW]
17KW
Number of cycles
> 6000 (70% DoD)
> 5000 (80% DoD)
> 4000 (90% DoD)
Temperature range in (ºC) Charge
From 0 to +50ºC
Temperature range in (ºC) Discharge
From -20 to +60ºC
Storage temperature (ºC)
From -20 to +45ºC
Storage temperature recommended (ºC)
From 15 to +25ºC
Power connector
Anderson SB175 (Wire
section 50mm2)
Anderson SB350 (Wire
section 70mm2)
Dimensions (L x P x A, mm)
Depending on the number of modules connected
Weight (Kg)
Depending on the number of modules connected
Degree of envelope protection
IP 30
Table 1.

www.cegasa.com
www.cegasa.com Page -6- User Manual R10 –First steps –
3 Safety
3.1 Symbols
Caution, electrical risk
Installation or manipulation near flammable materials is forbidden
Read the user manual before proceeding to the installation
Caution, high weight that can cause damage in a correct manipulation
of the equipment is done
Caution, corrosive substances
Use protection glasses
Do not dispose as domestic waste
Recyclable product
Disconnect the equipment before maintenance work
Caution in the manipulation of equipment sensible to electrostatic
electricity

www.cegasa.com
www.cegasa.com Page -7- User Manual R10 –First steps –
3.2 General information
The eBick is a smart energy storage system with Li-ion cells.
The whole system contains a high energy capacity. To minimize therisk of electric shock,
short-circuit, explosion and/or fire, follow the relevant procedures and local guidelines,
as well as the instructions that are included with the system.
Only qualified personnel should perform the installation, in accordance with the
applicable regulations. Systems with visible electrical connections have to be isolated
from public access. For safety reasons, cover all direct connections and terminals.
Carefully read, understand and apply all requirements presented in this section.
3.3 Safety instructions –Potential hazards
•The area around the eBick shall be kept clear and free of combustible
materials, gasoline and/or other flammable fumes, vapours and liquids.
•The area defined by safety margins for the necessary supply and venting
of air shall be respected.
•In the event of an emergency the eBick has electrical safety cut-off
elements (fuses and contactors). It is advisable to install an element that
protects against overcurrent and possible short-circuiting. It is also
advisable that the cut-off element can be manually operated if necessary.
Remember, because this is a battery the STRING’s internal DC bus will
always have a voltage.
•Do not use the module if any of its parts have been immersed in water.
A water damaged cell is potentially dangerous. Any attempts to use the
system could cause a fire or an explosion. In such cases, contact CEGASA
ENERGIA to have the battery pack inspected.
•The following instructions shall always be followed:
oAny air inlet or outlet within the room shall be kept clear and
free of obstacles.
oThe floor shall be capable of bearing the weight of the STRING.
oThere shall be no obvious signs of wear on any STRING
element.
oAs this is a battery, there is voltage on the +/- terminals
whenever the MCP contactor is closed.

www.cegasa.com
www.cegasa.com Page -8- User Manual R10 –First steps –
3.5 Electrical safety
•Never remove safety guards or devices that protect against live parts.
•Do not reach inside the STRING or the modules, nor touch any internal
component.
•Do not use or handle any eBick component when accidentally wet, or with
wet hands or feet.
•In the event of a failure or incident, as a first step cut off the current. To help
a person being electrocuted, do not touch them but immediately cut the
current. If it is not possible or takes too long to cut the current, try to
disengage them by means of an insulating element (wooden strip or board,
rope, wooden chair ...).
•Whenever a module is not installed on the STRING, make sure that the
power terminals at the front are protected against accidental contact.
•Make sure that the output and input connection cables are not short-
circuited.
•Make sure there is no short circuit between positive and negative terminals
at any point.
•Make sure there is always protective insulation on the output and input
cables and a reliable connection.
•Never use cables that are visibly damaged or that may be suspected of
being damaged.
•Minimise conductivity, avoiding surfaces in contact with water. Hands and
clothes have to be dry.
•Do not use, install or store the system under wet or damp conditions.
3.6 Mechanical safety
•Due to the weight of the battery modules (> 100 kg), mechanical means
have to be employed to install them.
•Do not stack eBick modules more than 4 high.
3.7 User requirements
In addition to personnel who work with the module, workplace users should also
implement safety measure by applying the minimum provisions of RD 614/2001 on the
protection of the health and safety of workers exposed to electrical risk in the workplace.
Hazards related to electrical risk are specifically identified during the work process with
this equipment. This does not exclude the possible existence of other risks present
during handling and use, such as overexertion, posture, or other measures against
health risks. Operators shall receive the necessary training, sufficient to be able to
prevent and avoid any risks arising from use of the equipment.
By design the equipment protects against these risks under normal operating conditions,
however, it is with operations that differ from normal ones (installation, maintenance, ...)
where special precautions have to be taken.
Particular care should be taken when handling modules, due to their weight. Respect
guidelines according to current regulations regarding ergonomics in the workplace
(Royal Decree 487/1997). Use appropriate handling equipment.

www.cegasa.com
www.cegasa.com Page -9- User Manual R10 –First steps –
3.8 Lockout-tagout of machines and installations (LOTO)
To perform operations absent of voltage (LOTO), the device must be locked and tagged
to non-hazardous voltage values. The following section is based on the lockout-tagout
at several points according to RD 614/2001:
1. Restrict access to the work area to prevent entry of unauthorised personnel.
2. It shall be disconnected and isolated from the supply network or the connection
to the converter.
3. Once disconnected, the STRING shall be sectioned into parts with voltages
below 75 VDC.
4. The terminals of these parts shall be protected by insulating caps designed for
this purpose.
5. Given that the batteries are an energy storage system, it is impossible to make
certain points of the system free of voltage. If there is any exposed point where
the voltage cannot be eliminated, the terminals will have to be tagged, indicating
the voltage value at that point.
6. Prior to conducting any work, the voltage shall be measured at the point where
the work is to bedone. Some points may beenergised directly from the batteries.
To carry this out, it is necessary to do the following:
•Use only 1000V insulated tools
•If terminals are exposed during the sectioning process, use 1000V rated
insulating gloves.
•Use a face shield during the work.
•Should it be necessary to perform an operation on a battery pack, place the
modules on Insulating matting.
•Use insulating footwear.
•To avoid possible short-circuiting, do not carry any conductive device (e.g.
pens, tape measures, etc.) during the work.
•Do not wear any metal, conductive or sharp-edged accessories.
3.9 Switching, measurements and checks
The regulation permits operations and interventions withoutlockout-tagout, provided that
an equivalent level of safety is guaranteed.
These interventions are called switching, trials and checks. They have to be carried out
by authorised personnel with protection devices and personal protective equipment
appropriate for the voltages in question.
It should be especially protected against short-circuits. Instructions to follow:
•The operations shall only be carried by authorised, duly trained, personnel.

www.cegasa.com
www.cegasa.com Page -10-User Manual R10 –First steps –
•Safety apparel that covers the whole body (long sleeves) shall be used.
Fireproof or flame retardant, with protection against chemicals and arc
flash.
•The work shall be done from a solid, stable support
•If a work table is used, it shall be insulated or covered with Insulating
matting.
•No terminal with an electrical charge should be left uncovered. If, after
removing the connections, the terminals are exposed then they have to be
protected with the terminal covers supplied.
•All tools shall be insulated and rated up to 1000V
•Insulating gloves, at least class 0 (1000V), shall be worn until existing
voltages are cut to levels below 50V DC.
•Operators shall not wear or carry any metal elements or devices.
•The work area shall be free of obstacles.
•If necessary, when there are exposed terminals nylon slings shall be used
instead of chains.
•The operator shall wear a face shield or safety glasses to protect against
short-circuits
•Occasionally, depending on the operation, there should be an OHS
assistant present.
•This person should satisfy that stated in Annex IV of RD 614/2001
4 Assembly of the equipment
Caution: Given that the modules are supplied with electrical charge levels necessary to
maintain the chemical properties of the batteries, the entire installation process shall
perform with the recommended protection equipment.
Each battery module and MCP are pre-wired, pre-set and factory tested. After receiving
and unpacking the system, the installer should find that each string contains:
-An MCP module
-Various eBick modules, these will be P or S depending on the system set-up.
-A BUS termination resistor
-S-BRIDGE CONNECTOR - Only for eBick-S set-ups connected in series
-PROTECTIVE COVER - Only for eBick-P set-ups connected in parallel
-One or more base frames with feet and wall or floor mounting plate/s
-A set of fastening plates for between modules, base frame and MCP (with
fasteners)
-A set of KIT communications and power extenders (*)
(*) Should the project have more than 4 modules, these have to be distributed in several
columns. The wiring between columns will be done using these extension cables.

www.cegasa.com
www.cegasa.com Page -11-User Manual R10 –First steps –
4.1 Potential hazards
4.2 Initial check
Before beginning the installation, it is advisable to check the state of the modules:
1. Check the state ofthe modules No knocks or apparent damage; Thenameplate
bearing the serial number fitted to the back of it.
2. With the aid of a multimeter measure DC voltage between the positive and
negative terminals on each battery module (points 1 & 2). Check that polarity is
correct and that the voltage is within range (≈ 48VDC)
The retractable red lug on the cable indicates positive polarity, while its absence
indicates negative polarity. On eBick-S type modules, 2 of the pins have no
voltage. The diagram below shows the correct measurement points.

www.cegasa.com
www.cegasa.com Page -12-User Manual R10 –First steps –
3. Check the state of the MCP. No knocks or apparent damage.
4.3 Fitting the modules
1. First place the base frame on the floor and use the feet to level it. If required,
secure the string to the floor, the base frame has a space where brackets can be
fitted. The eBick system is designed to be stationary, with no possibility of
movement and with its weight distributed evenly.
2. Stand the first eBick module on the base frame that is already level and fixed to
the floor. Any module can be inserted in any order in the string, without affecting
power or communications.
3. Stack the rest of eBick modules up to a maximum of 4 high.

www.cegasa.com
www.cegasa.com Page -13-User Manual R10 –First steps –
4. Place the MCP on top of the last module and check that the ON/OFF switch at
the back is in the OFF position.
5. Use the fastening plates to fasten all theeBick modules to each other, to the base
frame and to the front of the MCP. Note: Screw length is different when fastening
the MCP (see picture below)

www.cegasa.com
www.cegasa.com Page -14-User Manual R10 –First steps –
6. Assemble the “N” columns that go to form the installation project in the same way
as indicated in the previous steps but without the MCP, which is already fitted on
the first column.
7. Communication connection between modules; starting with the MCP, make the
communication connections between modules using the Male-Female
communication connectors on the left.
If there are several columns in the project, use the Communications Cable
Extender Kit to make the communication connections.
2 x metal screw M6x10
✓BASE FRAME - eBick
UNION
✓eBick - eBick UNION
2 x metal screw M6x20
✓MCP eBick UNION
Communications EXTENDER KIT

www.cegasa.com
www.cegasa.com Page -15-User Manual R10 –First steps –
On the last eBick module, fit the bus termination resistor on the connector that is
free.
8. Power connection between modules; First check to see if the installation is in
series or parallel and make sure to use PPE (protective gloves and safety
glasses)
8.1 Parallel connection (voltage 48V) - For eBick P cases (Anderson 350)
✓Without connecting to the MCP (leave this until last) start connecting all the
power connectors between columns; If there are several columns, use the
PARALLEL POWER CABLE EXTENDER KIT at the rear.
✓Use the supplied protective cap to protect the power connector left
uncovered on the last eBick module.
BUS termination resistor
POWER EXTENDER KIT
PARALLEL
Anderson connector
SB350

www.cegasa.com
www.cegasa.com Page -16-User Manual R10 –First steps –
✓Check polarity and voltage (close to 48Vdc) on the power connector below
the MCP
✓Use the multimeter to check that there is no continuity between positive and
negative on the MCP power connector (no beep)
✓If everything is OK, proceed to connect the MCP connector to the already
connected DC BUS connector.
8.2 Series connection (voltage 48V) - For eBick S cases (Anderson SB175)
✓Without connecting to the MCP (leave this until last) start connecting all the
power connectors between columns; If there are several columns, use the
SERIES POWER CABLE EXTENDER KIT at the rear.
✓Connect the S BRIDGE CONNECTOR to the connector on the last free
module in order to close the VDC BUS
POWER EXTENDER KIT
SERIES
Anderson connector
SB175

www.cegasa.com
www.cegasa.com Page -17-User Manual R10 –First steps –
✓Check polarity and voltage (close to “Nº modules connected x 48Vdc”) on
the power connector below the MCP.
✓Use the multimeter to check that there is no continuity between positive and
negative on the MCP power connector (no beep)
✓If everything is OK, proceed to connect the MCP connector to the already
connected DC BUS connector.
9. At the back of the MCP, connect the earth connection (M-6 bolt) to the earth for
the installation. An earth cable of between 1mm2- 2.5 mm2section should be
used (See point 7 in image below)
10. Check at the back of the MCP that there is no voltage or continuity between the
poles on the positive and negative power output connectors. (See points 4 and 6
in image below)
11. At the back of the MCP connect the terminals (M-8) that corresponds to the
installation’s positive and negative terminals. The recommended tightening
torque is 10Nm using a torque wrench. (See points 4 and 6 in image below)
12. At the back of the MCP connect the correct RJ45 communication connectors for
the inverter (MODBUS or CAN BUS). It is recommended that the cable length is
no longer than 20 metres.

www.cegasa.com
www.cegasa.com Page -18-User Manual R10 –First steps –
Important notes:
✓The system is self-powered and does not require connection to an external
supply.
✓The length of the interconnecting cables affects the final voltage detected by the
application. It is advisable to install the battery as close as possible to the element
that is going to use it (inverter, DC bus, ...) and avoid sharp curves or bends in
the cables. For recommended cable lengths, wire sizes and characteristics,
please contact CEGASA.
5 Commissioning the equipment
5.1 System start-up and shut-down processes
All points included in the previous section should have been followed prior to starting the
system. Once this has been done, the system can be started by pressing the switch on
the MCP from the OFF to ON position.
Pressing the switch powers up the control electronics in the MCP. The GBMS then
checks hardware integrity (own hardware and that of the BMS distributed by
communications) andthat the cabinet distribution set-up corresponds with that read (see
point 4.3). If no error is detected, the GBMS allows work with batteries to commence.
The time required for start-up is less than 1 minute.
To stop the system, the same switch should be changed from the ON to OFF position.
The string should never be switched off while current is flowing through the system. The
contactor has to be opened prior to switching off the MCP.
HAZARD: ELECTRONICS SELF-CONSUMPTION
The electronics inside the cabinet are powered by the batteries. If the
batteries are not going to be used for a prolonged period (3-4 weeks), the MCP
has to be turned off manually by pressing the ON/OFF button to OFF.
5.2 Power connection process
eBick systems can operate in 2 different ways: Slave Mode and Stand-alone Mode, it is
advisable ask the supply company in which mode the MCP is configured before the
system is started.