Saft 777308-00 User manual

INDUSTRIAL BATTERY GROUP
Doc Ref:
ED2015-0544
User’s Manual
Lithium-ion Battery System (504V / 45 Ah)
Type of document:
User Manual
Created on: 04/12/2015
This document is Saft property. Any reproduction, diffusion or communication, even partial, are liable to prosecution without formal authorization.
Lithium-ion Stationary Battery System
P/N 777308-00
BTR-0504V-VL45E-NCA-009M
504V / 45Ah

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DOCUMENT REVISION
Version
Date
Changes
1
04/12/2015
First issue 9 Synerion modules version based on the ED2014-
0210_UM_10 Syn48E battery_rev2

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It is mandatory to read the user and the maintenance manuals prior to any use,
installation or maintenance of a Saft battery. All instructions must be carefully complied
with. In case any of the instructions contained in the user and the maintenance manuals
are not applied, Saft’s warranty on the battery is no longer applicable and Saft disclaim
any liability for any and all direct, indirect or consequential damages or losses resulting
thereof.
To highlight important points, the following symbols will be used:
Indicates a possibility of injury or serious equipment damage if instructions are not
followed
Indicates helpful information

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SAFETY RULES
All the recommendations contained in this document must be applied and respected.
(1) Always use the batteries with restrictive access. Battery must remain
accessible only to trained service personnel.
(2) Install in a location that could be easily ventilated in case of misuse of
batteries such as described below.
(3) Misusing the batteries may cause them to overheat or ignite and cause
serious injuries. Make sure to follow the safety rules listed below:
Never short-circuit the battery terminals
Do not reverse the polarity
Do not overcharge or over-discharge
Respect the voltage range given in this manual.
Do not open the battery or modules
Do not disassemble the unit
Do not use the unit without its electronic management system
Do not subject to excessive mechanical stress
Do not expose the unit to water or condensation
Install the batteries in an area compatible with pollution level 2 according
to EN 60664-1 (typical of office or laboratory environments).
(4)Do not place the batteries on or near fires or other high-temperature locations
(> 70°C). Doing so may cause the batteries to overheat or ignite. Using the
batteries in this manner may also result in a loss of performance and a
shortened life expectancy.
(5)Immediately disconnect the batteries if, during operation, they emit an
unusual smell, feel hot, change shape, or appear abnormal in any other way.
Contact SAFT if any of these problems are observed.
(6)Prior to use the batteries, read carefully the Material Safety Data Sheet
supplied with the batteries.
(7)The battery systems must be used with the Synerion 48E modules described
in paragraph 2. Saft does not assure the behavior and the safety of the
battery system if another module is used.
(8)In case of contactor stuck closed (Alarm 18 rising), stop immediately the
battery charge or discharge.

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TABLE OF CONTENTS
1. INTRODUCTION ..................................................................................................................7
1.1. Applicability.....................................................................................................................7
1.2. Acronyms........................................................................................................................7
1.3. Symbols..........................................................................................................................8
1.4. Referenced documents...................................................................................................8
2. UNPACKING AND INSPECTION.........................................................................................9
2.1. Battery characteristics...................................................................................................11
3. GENERAL DESCRIPTION OF THE BATTERY SYSTEM.................................................13
3.1. Synoptic........................................................................................................................13
3.2. Battery system..............................................................................................................14
3.2.1. Li-ion Modules........................................................................................................14
3.2.2. BMM.......................................................................................................................14
3.3. HMI...............................................................................................................................15
3.4. Assembly installation ....................................................................................................16
3.5. Battery start-up.............................................................................................................16
3.6. Battery shutdown..........................................................................................................16
3.7. Gas exhaust..................................................................................................................16
3.8. Electrical interfaces.......................................................................................................17
3.8.1. Power connection...................................................................................................17
3.8.2. Electrical connection ..............................................................................................17
3.8.3. Communication connector......................................................................................19
3.8.4. Power supply connector.........................................................................................19
3.8.5. Earth connection ....................................................................................................19
3.8.6. Diagnostic interface................................................................................................20
4. BATTERY MANAGEMENT and Operating instructions.................................................21
4.1. General principle...........................................................................................................21
4.2. Safety functions ............................................................................................................21
4.2.1. Over charge protection...........................................................................................21
4.2.2. Over-discharge protection......................................................................................22
4.2.3. Over temperature protection...................................................................................22
4.2.4. Over current protection...........................................................................................22
4.3. Communication.............................................................................................................23
4.4. Operation during storage & maintenance .....................................................................23
4.5. Operational states.........................................................................................................24
4.6. Precharge .....................................................................................................................25
4.7. Battery charging............................................................................................................26
4.8. Charge profile description.............................................................................................26
4.9. Battery discharging.......................................................................................................28
4.10. Complete discharge & sleep mode............................................................................28
4.11. Alarms and warnings.................................................................................................28
4.12. Balancing...................................................................................................................29
4.13. Displayed information................................................................................................29
4.14. Communication with application................................................................................29
4.14.1. Data sent by BMM to EMS..................................................................................29
4.14.2. Data received by BMM from EMS.......................................................................30
4.15. SOH and EOL definitions...........................................................................................31
4.16. SOC definitions..........................................................................................................31
5. COMMISSIONING AFTER LONG STORAGE...................................................................31
6. HANDLING & STORAGE OF THE BATTERY MODULES................................................33
6.1. Handling........................................................................................................................33
6.2. Storage.........................................................................................................................33
6.2.1. Storage location .....................................................................................................33

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6.2.2. Battery state of charge checking............................................................................33
6.2.3. Battery recharge in storage....................................................................................33
7. MAINTENANCE .................................................................................................................34
8. PACKAGING AND TRANSPORT......................................................................................35
8.1. Battery classification.....................................................................................................35
8.2. Training.........................................................................................................................35
8.3. Battery packing.............................................................................................................35
8.4. Charging state for transportation...................................................................................35
8.5. Document used for transportation.................................................................................35
9. DISPOSAL .........................................................................................................................36
10. APPENDIX I: Module Mechanical drawing...................................................................37
11. APPENDIX II: BMM Mechanical drawing......................................................................38
12. APPENDIX III: Power cable connection drawinG ........................................................39
13. APPENDIX IV: Termination connection drawing (771611)..........................................40
14. APPENDIX V: Inter modules connection drawing (771596)........................................41
15. APPENDIX VI: Module to BMM connection drawing (772872)....................................42
16. APPENDIX VII: Fault codes and alarm list of the battery system ..............................43
LIST OF FIGURES
Figure 1: Synerion 48E module....................................................................................................9
Figure 2: Battery Management System........................................................................................9
Figure 3: Power cable connection for 9 modules battery ...........................................................10
Figure 4: Communication ribbon cables.....................................................................................10
Figure 5: Battery synoptic ..........................................................................................................13
Figure 6: BMM HMI....................................................................................................................15
Figure 7: -polarity power connector............................................................................................17
Figure 8: +polarity power connector...........................................................................................17
Figure 9: Battery connection......................................................................................................18
Figure 10: CAN connector..........................................................................................................19
Figure 11: Power Supply connector...........................................................................................19
Figure 12: Diagnostic connector ................................................................................................20
Figure 13: Battery modes...........................................................................................................24
Figure 14: IMR & IMR_C versus SOC profile.............................................................................26
Figure 15: Battery charge profile................................................................................................27
Figure 16: VL45E normal rate charge profile (IMR & IMR_C vs T°C)........................................27

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1. INTRODUCTION
This document contains the operating rules of the SAFT Lithium-Ion battery unit model for
Stationary Batteries 9 modules 504V max with limitation at 486V P/N 777308-00.
1.1. Applicability
This document describes functionalities and behaviour implemented in the BMM software
version 0.65 revH.
1.2.Acronyms
Acronym
Definition
Application
BMM
Equipment connected to the battery and consuming current from or feeding current to the battery
Battery Module Management
BMU
CAN
Battery Management Unit
Controlled Area Network
EDU
Electro-technical Device Unit
EMS
EOL
HMI
HVIL
Energy Management System
End Of Life
Human to Machine Interface
High Voltage Interlock Loop
I/O
Input / output signal
IMD
Maximum current allowed in discharge
IMR
Maximum current allowed in charge
Li-ion
Lithium Ion
MBMM
Master Battery Monitoring Module
N/A
N/U
PBIT
PoffBIT
P/N
Not Applicable
Not Used
Power on Built In self Test
Power off Built In self Test
Part Number
SMU
Safety Monitoring Unit
SOC
State Of Charge (Battery)
SOH
State Of Health (Battery)
TBC
To Be Confirmed

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1.3.Symbols
Direct current
Caution
Caution, possibility of electric shocks
Li-ion recycling
1.4.Referenced documents
A reference document is used as a basis of work. Its strict application cannot be required.
: Document title
Emitter
Reference
Rev
[RD1] CAN OPEN dictionary for BMS
SAFT
SDU/SEL/DH 09-0974
L
[RD2] Diagnostic WinBMS Software User
Manual
SAFT
User_Manual_WinBM
S_11-1093
7
[RD3] Uninterruptible power systems
Electromagnetic compatibility (EMC)
requirements
-
CEI_62040_2
EN61000-6-2
EN61000-6-3
2006_06
2006_01
2007_03
[RD4] Electronic equipment for use in power
installations
-
NF_EN_50178
1999_10
[RD5] Transport of Lithium batteries
-
UN 3480
-

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2. UNPACKING AND INSPECTION
Each module is packed separately. The BMM, connection kit and documentation are packed
together.
Check the packing material for any damages before accepting delivery from the carrier. If there
is any sign of damage, report it to the carrier and to SAFT and make a “certified letter with
acknowledgement” to the transporter.
For each battery system, ensure that the following parts are delivered:
9 Synerion 48E modules / 48V nominal / 45Ah: P/N 774842-00
Figure 1: Synerion 48E module
1 BMM: P/N 776354-01
Figure 2: Battery Management System

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Connection Kit:
oPower cable to connect modules and BMM (see drawing on Appendix III):
Figure 3: Power cable connection for 9 modules battery
oCommunication ribbon cables kit to connect modules and BMM:
Figure 4: Communication ribbon cables
1 CDROM or USB key with SAFT diagnostic software (DiagWinBMS) and its
User Manual
It is advised to save the original packaging for reuse in case of later shipment.
Termination connection: P/N 771611
- 1 per battery
(see drawing on Appendix IV)
Inter-module connection: P/N 771596
- 8 for 532V battery
(see drawing on Appendix V)
Module to BMM
connection: P/N 772872
- 1 per battery
(see drawing on Appendix VI)