Maxwell 16 V Series User manual

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USER MANUAL
Maxwell Technologies®
Ultracapacitor Energy Storage Modules
Models:
16 V Series:
48 V Series:
BMOD0500 P016 B01
BMOD0500 P016 B02
BMOD0250 P016 B01
BMOD0110 P016 B01
BMOD0165 P048 B01
BMOD0110 P048 B01
BMOD0083 P048 B01
BMOD0165 P048 B06
BMOD0165 P048 B09
Document 1008491
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1. Introduction
The 16 V and 48 V series energy storage modules are self-contained energy storage devices
comprised of either six or eighteen individual ultracapacitor cells, respectively. The modules
include bus bar connections and integrated cell balance voltage management circuitry. Units may
be connected in series to obtain higher operating voltages, parallel to provide additional energy
storage, or a combination of series/parallel arrangements for higher voltages and energy. Voltage
management and alarm circuits function to protect each cell from operating in a damaging
overvoltage condition.
The module packaging (except for BMOD0110 P016) is a heavy-duty aluminum extruded
enclosure. The enclosure is a sealed, water-resistant device (per IEC 529 –IP65). The package
for the BMOD0110 P016 consists of a plastic housing with a metallic cover for thermal transfer.
The voltage management electronics have a single open collector logic output (except for models
with “B02” suffix) which indicates if any cell within the module is experiencing an over voltage
condition. Each module contains one temperature monitor output in the form of an NTC
thermistor.
2. Unpacking and Handling
Unpacking2.1
Inspect the shipping carton for signs of damage prior to unpacking the module. Damage to the
shipping carton or module should be reported to the carrier immediately. Remove the module from
the shipping carton and retain the shipping materials until the unit has been inspected and is
determined to be operational.
The following items are included with the module:
1 x Product Information Sheet
1 x Certificate of Conformance
1 x Hex head cap, M10x16, Zinc plated screw
1 x Hex head cap, M8x16, Zinc plated screw
NOTE: The original shipping materials are approved for both air and ground shipment. The
module should be removed from the shipping carton by lifting it by the module body and not by
the terminal posts.
If the unit is found to be defective or any parts are missing, contact your supplier. A Return
Material Authorization (RMA) number must be issued prior to returning the unit for repair or
replacement.
Handling2.2
Maxwell ultracapacitor modules are designed to provide years of trouble-free operation. Proper
handling is required to avoid damage to module. In particular, the following handling precautions
should be observed:
Do not stack modules once they have been removed from the shipping containers.
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Do not drop modules. Internal damage may occur that will not be visible from the
exterior.
Do not step on modules.
Protect the PCBA cover from impact. If any damage occurs to the PCBA cover, contact
Maxwell for replacement instructions.
Do not use tools such as hammers to disengage mounting or terminal bolts. Serious
damage may occur.
3. Installation
Mechanical3.1
Modules may be mounted and operated in any orientation. Two mounting surfaces are available
(except for BMOD0110 models); one at the top and the other at the bottom surface. These top
and bottom plates are designed to support the module with no additional mechanical contact. See
the data sheet for available mounting locations. The BMOD0110 models may only be mounted with
the bottom side down to the mounting surface.
For best results the modules should not be mounted in locations where they are directly exposed
to the environment. In particular, areas of direct splash should always be avoided. In systems
that operate at voltages in excess of 60 V, appropriate protection and sealing should be used on
both module terminals to avoid shock hazards and corrosion.
A proper installation should not exert any bending or twisting torque to the module enclosure.
Ensure that the module’s mounting points are co-planar within ±1 mm. If the actual mounting
location is out-of-plane, use spacers to bring all four mounting locations within plane to within
±1mm.
Modules (except for BMOD0110 P016) have been qualified to SAE J2380 for vibration performance.
Ensure that this is adequate for the end-use environment.
Each module is provided with a threaded vent hole on the top plate. The module is shipped from
the factory with a vent plug in this vent hole. The use of the vent is optional. If the application
recommends/requires remote venting, a threaded hose barb can be provided upon request.
To use the hose barb, remove the vent plug which is in the hole when the module is received and
replace it with the hose barb. Attach a 5/32 (4 mm) ID hose, preferably Teflon or polypropylene,
to the hose barb and route the hose to a safe venting location. In the event of cell venting, the cell
may release gas, which will build pressure in the module. That pressure can be relieved through
the vent tube.
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Electrical3.2
WARNING
To avoid arcing the energy storage module should be in a
discharged state and the system power disconnected during
installation. The module is shipped discharged and with a shorting
wire. The shorting wire should be removed prior to electrical
connections.
To provide the lowest possible ESR the energy storage modules are
not fused. Care should be taken within the application to prevent
excessive current flow as required. Excessive current and/or duty
cycle will result in overheating the module which will cause
irreparable damage. Please consult the specific data sheet for each
module for current and duty cycle capabilities.
Module-to-module cabling should be sized for the applications peak and/or RMS current.
Undersized cables may cause excessive cable or interconnect temperature rise and system
electrical resistance. High resistance wiring/cables or module power connections will increase
terminal cell temperature and degrade module lifetime and long term performance. Reference
applicable wire sizing guides. Wire temperature must not exceed module temperature.
Note: The module chassis should be grounded to the system chassis through any of the module
mounting holes. Refer to applicable ground wiring guides and standards for the application.
The anodized coating of the module on the ground connection surface should be removed to
ensure an optimal electrical contact. Apply a layer of high conductivity anti-oxidant joint compound
between the mating surfaces (IDEAL Noalox®Anti-Oxidant Compound or equivalent).
3.2.1 Output Terminal Posts
The output terminals of the module consist of internally threaded aluminum posts. They are
designed to connect directly to a ring lug or a bus bar. Maximum thread depth is 20 mm. If ring
terminals and lock washers in excess of 10 mm are to be used, a longer bolt must be selected. In
no instance should the total amount of thread engagement be less than 10 or greater than 20 mm.
The terminal contact surface should be cleaned with a light abrasive such as Scotch-BriteTM to
remove any oxidation. Apply a layer of high conductivity anti-oxidant joint compound between the
mating surfaces (IDEAL Noalox®Anti-Oxidant Compound or equivalent). The positive terminal is
threaded for M8 x 1.25 steel bolts. The negative terminal is threaded for M10 x 1.5 steel bolts.
Lock washers are required for long term, reliable connections. For additional performance, a
thread locking compound such as Loctite®425 may be used. However, care should be taken that
the thread locking compound does not come in contact with the electrical mating surfaces.
When tightening the terminal bolts, a torque of 20 N-m / 14.8 ft-lbs for the M8 and 30 N-m / 22.1
ft-lbs for the M10 bolts should be used. Do not exceed recommended torque.
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As in any electrical system, proper cable dress is required for trouble-free operation. The cables
used for attachment are large, and improperly constrained cables can place bending stress on the
terminals and terminal bolts. Cables should be installed so that they do not exert bending or
twisting torque on the power terminals, and should be routed away from the module so that they
are parallel to the top surface of the terminal and constrained within 50 cm of the terminal before
bending the cable in any direction. High vibration environments may require additional restraints.
Attachment to the output terminals should be made with ring lugs or bus bars of an appropriate
size for the application current. If bus bars are used, brackets should be installed to interconnect
the tops of adjacent modules to prevent undesirable lateral forces on the terminals.
The energy storage modules have low ESR. As a result, the resistance of the wires connecting the
energy storage module to the application can easily exceed the ESR of the module. Connection of
modules in series or parallel should utilize the same gauge wire (or equivalent bus bar) as
determined for final output connections. When connecting in series connect the positive output
terminal of one module to the negative output terminal of the next module. Two possible
orientations are illustrated in Figure 1.
Figure 1 –Possible series connection arrangements
Full UL810a compliance is satisfied for up to three (3) BMOD0165 P048 (certain BMOD0165 P048
B09 models may not be UL810a compliant) modules in series or nine (9) BMOD0500 P016 modules
in series (maximum operating voltage of 150V).
When several modules are connected in series for operating at higher voltage, care must be taken
to ensure proper creepage and clearance distances in compliance with national safety standards
for electrical equipment.
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3.2.2 Module to Module Connections
The 16 V and 48 V modules are equipped with the active voltage management circuit that protects
and monitors every cell within the module. Module-to-module balancing is not required.
Figure 2 –Series Connection of 48V Modules
Figure 3 –Parallel Connection of 48V Modules
3.2.3 Logic outputs
A single open collector logic output is available for overvoltage monitoring. This output will indicate
if any cell in the module has gone into an overvoltage condition. In addition, the output of the
NTC thermistor is also available for module temperature monitoring. The overvoltage signal and
temperature signal are available via the connector supplied with the module. Note: The passive
version (suffix “B02”) of the BMOD0500 only provides the output of the NTC thermistor for the
temperature monitor signal. There is no voltage monitoring signal in this module.
The logic outputs are isolated from the capacitor voltages and from chassis ground. The logic
outputs may be operated individually or wire-or’d to provide a single fault line. A table indicating
the pin out, indication and maximum current is provided below.
Pin
#
Wire
Color
Pin out
designation
Output
(16 V)
Output
(48 V)
Maximum
current
1
Black
GRND
2
White
Overvoltage
Alarm
High –
Inactive
Low - Active
High –
Inactive
Low - Active
5 mA
3
Red
Not used
N/A
N/A
N/A
4
Green
TEMP
NOTES:
1. Pin #2 is not used for the BMOD0500 P016 B02 model with passive balancing.
2. The Overvoltage Alarm will be asserted if any individual cell goes into an over voltage
condition. The range of the alarm threshold is as follows:
2.73V minimum
2.80V nominal
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2.86V maximum
3. The Overvoltage Alarm Signal (Pin 2) is an open collector output indicating when the voltage
management electronics are active. In order to use the signal, the user must connect a pull-up
resistor (≥1kΩ) between Pin 2 and a nominal 5V (maximum 5.5V) supply. In this
configuration, the voltage at Pin 2 will be ~ 5V when the circuit is not active. When a cell in the
module goes into an overvoltage condition, the output of Pin 2 goes low. The Overvoltage
Alarm can be used as a signal to the system electronics to stop charging in order to protect
cells from damage. When an acceptable cell voltage is reached, the output goes high again
and can be used as a signal to resume charging. Figure 4 shows a typical connection to use
this system.
4. The Overvoltage Alarm circuit can sink up to 5 mA with a VOL of no more than 0.4V. The
leakage current when the output is off is 50 nA. The proper value of the pull-up resistor
should be calculated based upon overall system circuit design.
Fig. 4 –Typical connection to the monitor cable. (Users to verify values based on their circuit
design)
The temperature output operates at any module voltage including zero volts.
The TEMP output is via a NTC thermistor and can be measured between pin 4 and pin 1 (GND) of
the connector. The resistance of the thermistor varies with temperature to provide the actual
temperature of the module. The thermistor is located inside the module. Under normal operating
conditions the temperature output should represent the module’s hottest location. The resistance
measured through the thermistor relates to temperature according to a US Sensor thermistor with
a nominal value of 10K@ 25ºC (reference temperature chart for the 103JM1A.)
http://www.ussensor.com/rt charts/103JM1A.htm
A mating connector for these signals is provided with 6” (15 cm) of cable length. Additional 22
gauge wire may be spliced for longer wire length up to 6 feet (1.8 m). For lengths longer than 6
feet (1.8 m) shielded 4 conductor wire is recommended.
Thermal Performance3.3
Low internal resistance of the energy storage modules enables low heat generation within the
modules during use. As with any electronic component, the cooler the part operates the longer
the service life. In most applications natural air convection should provide adequate cooling. In
severe applications requiring maximum service life, forced airflow or a liquid-cooled cold plate may
be required.
The thermal resistance, RTH , of the units has been experimentally determined assuming free
convection at ambient temperature (~ 25oC). The RTH value provided on the datasheet is useful
for determining the operating limits for the units. Using the Rth value a module temperature rise
can be determined based upon any current and duty cycle. The temperature rise can be
expressed by the following equation.
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fTHESR dRRIT 2

where:
I= RMS current (amps)
RESR = equivalent series resistance, RDC (ohms)
RTH = thermal resistance (oC/W)
df= duty cycle fraction
The T value calculated above plus ambient temperature should remain below the specified
maximum operating temperature for the module (please refer to the module datasheet) as
measured by the thermistor output. If active cooling methods are employed, it is possible to
operate at higher currents or duty cycles than if only passive cooling is utilized.
4. Operation
The module should only be operated within specified voltage and temperature ratings. Determine
whether current limiting is necessary based on the current ratings of attached components.
Observe polarity indicated on module. Do not reverse polarity.
5. Safety
DANGER
HIGH VOLTAGE HAZARD
Never touch the power terminals as the module can be charged and
cause fatal electrical shocks. Always verify that the module is fully
discharged before manipulating the module. Refer to the instructions
below for the manual discharge procedure.
Do not operate unit above the specified voltage.
Do not operate unit above the specified temperature rating.
Do not touch terminals with conductors while charged. Serious burns,
shock, or material fusing may occur.
Protect surrounding electrical components from incidental contact.
Provide sufficient electrical isolation when working above 50 V DC.
Prior to installation on or removal from the system, it is mandatory to
fully discharge the module to guarantee the safety of all personnel.
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WARNING
A fully discharged module may “bounce back” if it is stored without a
shorting wire connected to the + and –terminals. This bounce back can
be as much as 6V for the 48V module and is enough to cause
dangerous electrical shocks.
Discharge Procedure5.1
To discharge an individual module:
1. Using a voltmeter, measure the voltage between the two power terminals.
2. If the voltage is above 2V, a power resistor (not supplied with the module) may be
connected between the terminals to discharge the module. Proper care needs to be taken
in the design and construction of such a resistor. Resistor value will change discharge time,
current, power and temperature.
Note: Customers may instead wish to consider using a DC electronic load tool to support
the safe/controlled discharge of individual modules prior to service (for example, the BK
Precision DC Electronic Load Model 8500 or a similar tool).
3. If the voltage is under 2V, connect the shorting wire provided by Maxwell to the + and –
connectors.
4. The module is now safe for handling. However, leave the shorting wire connected at all
times until the module is installed in the system and the power cables are connected.
6. Maintenance
Prior to removal from the system, cable removal, or any other handling ensure that the energy
storage module is completely discharged in a safe manner. The stored energy and the voltage
levels may be lethal if mishandling occurs. Maintenance should only be conducted by trained
personnel on discharged modules (see “Discharge Procedure” above).
Routine Maintenance6.1
1. To improve power dissipation performance, clean the exterior surface of dirt/grime. Use a
cleaning cloth dampened with a water/soap solution. Do not use high-pressure sprays or
immersion. Keep excess amounts of water away from the PCBA cover and power terminals.
For outside use, do this every 6 months, or as needed. For inside use, you can do this
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annually.
2. To avoid mechanical damage, check mounting fasteners for proper torque. In high-
vibration environments, do this every 6 months. In low-vibration environments, do this
annually.
3. Regularly inspect housing for signs of internal damage. Do this every 6 months for outside
use, and annually for inside use.
4. Check signal/ground connections to avoid false signals or shock hazards. In high-vibration
environments, do this every 6 months, and in low-vibration environments, do this annually.
7. Storage
The discharged module can be stored in the original package in a dry place. Discharge a used
module prior to stock or shipment. A shorting wire across the terminals is strongly recommended
to maintain a short circuit after having discharged the module.
8. Disposal
Do not dispose of module in trash. Dispose of according to local regulations.
9. Specification
Refer to datasheets at our website, www.maxwell.com, for specifications for each specific product.
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