Superb SB12V100E-ZC User manual

Manual
13.2V/100 Ah
(1.3kW LiFePO4)
LITHIUM BATTERY
SB12V100E-ZC

2
User Manual SB12V100E-ZC Lithium Iron Phosphate battery
Dear customer,
This manual contains all the information necessary to install, use and maintain the SuperB
SB12V100E-ZC Lithium Iron Phosphate Battery. We kindly ask you to read this manual
carefully before using the product. In this manual, the SB12V100E-ZC battery will be referred
to as: the Li-Ion battery.
This manual is meant for the installer and the user of the Li-Ion battery. Only qualified,
certified personnel may install and perform maintenance on the Li-Ion battery.
Please consult the index at the start of this manual to locate information relevant to you.
This is the original manual, keep it in a safe location!
Copyright©Super B b.v. All rights reserved. Licensed software products are owned by
Super B or its subsidiaries or suppliers, and are protected by national copyright laws and
international treaty provisions. Super B products are covered by Dutch and foreign patents,
issued and pending. Information in this publication supersedes that in all previously published
material. Specifications and price change privileges reserved. Super B is a registered
trademark of Super B b.v.
For more information, or to order documents, contact:
Super B b.v.
Diamantstraat 1e
7554 TA Hengelo (Ov)
The Netherlands
Tel: [phone]
Fax: [phone]
E-mail: [e-mail]
www: www.super-b.com

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Table of content
1. Introduction 5
1.1. Product description 5
1.2. Glossary of Terminology 5
1.3. Used symbols 6
2. Product specifications 6
2.1. Product features 6
2.2. General product specifications 6
2.3. Technical specifications 7
2.3.1. Battery designation 7
2.3.2. Electrical properties 7
2.3.3. Dimensions 8
2.4. Environmental conditions 8
2.5. Required tools 9
2.6. Components 9
2.6.1. List of components 9
2.7. Connections, indicators and battery controls 10
2.7.1. Con1 (I/O Connection 4) 11
2.7.2. Con2 (I/O connection 7) 11
2.8. Peripheral equipment 11
2.8.1. Obligatory 11
2.8.2. Optional 12
3. Safety guidelines and measures 12
3.1. General 12
3.2. Installation 12
3.3. Use 13
3.4. Disposal 13
3.5. Safety symbols and markings on product 13
4. Installation 14
4.1. General information 14
4.2. Unpacking 14
4.3. Preparing the battery for use 14
4.3.1. Placement of the battery 14
4.3.2. Placement and removal of a fuse 15
4.4. Connection wires 16
4.5. Installing the battery in an electrical circuit 16
4.5.1. Installing a Battery Disconnect device, 16
4.5.2. Connecting CANopen interface 17
4.5.3. Connecting the battery to the load 19

4
4.5.4. Connecting a charger to the battery 21
4.5.5. Disconnecting a battery 21
4.5.6. More configuration options 22
5. Battery use 25
5.1. General information 25
5.2. Charging 25
5.2.1. Charging rate 25
5.2.2. Charging method 25
5.2.3. Battery balancing 27
5.2.4. Serial String balancing 28
5.2.5. Determining the battery’s state of charge (SoC) 28
5.3. Battery use 29
5.3.1. Battery fault condition 29
5.4. Battery Monitoring Software 29
5.4.1. Continuous Battery Monitoring 30
5.4.2. Battery History Recording 31
6. Inspection, cleaning and maintenance 31
6.1. General information 31
6.2. Inspection 31
6.3. Cleaning 32
6.4. Maintenance 32
7. Storage 32
8. Transportation 32
8.1 General 32
9. Disposal and recycling 33
9.1. General information 33
10. Troubleshooting 34
11. Warranty and liability 36
Appendix I Declaration of Conformity 38
Appendix II Certificate of Compliance 39
Appendix III Performance Graphs 40
Appendix IV Conductor requirements 42

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1. Introduction
1.1. Product description
The SB12V100E-ZC is a Lithium Iron Phosphate rechargeable battery. Potential applications
of this battery include: off grid power supply, marine power supply, medium for (renewable)
energy storage (traction) battery for vehicles. The boundaries of its use, as described in
this manual should always be upheld. The Li-Ion battery may not be used in medical or in
aviation related applications. The Li-Ion battery may not be used for any purposes other than
described in this manual. Using the battery for any other purpose will be considered improper
use and will void the warranty of the product. Super B b.v. cannot be held responsible for any
damage caused by improper, incorrect or unwise use of the product. Read and understand
this manual completely before using the product.
Super B provides a CE declaration of conformity (appendix 1) and a Certificate of Compliance
(appendix 2) for the product. In accordance with CE guidelines, a design and manufacturing
schedule is available. A Material Safety Data Sheet is also available.
The SB12V100E-ZC complies with the following council directives:
• 2006/66/EC on Environmental EU Compliance
• 2004/108/EC (December 15, 2004) on Electromagnetic Compatibility
The SB12V100E-ZC complies with the following standards:
• EMC: Emission - EN61000-6-3 (2007) +A1 (2001); Immunity - EN6100-6-2 (2005) + AC (2005)
• IEC 62133, Safety IEC Compliance
• IEC 61960{ed2.0}, Performance IEC Compliance
• IEC 62281, Transportation IEC Compliance
During the use of the product, user safety should always be ensured, so installers, users,
service personnel and third parties can safely use the product. The user must always have
access to this manual; keep it in a safe accessible location.
1.2. Glossary of Terminology
Endurance Life-cycle: The products maximum lifespan, achieved by adhering to the
guidelines presented in this manual.
Charge cycle: A period of use from fully charged, to fully discharged, and fully
recharged again.
BCI: Battery Communication Interface
SoC: State of charge

6
1.3. Used symbols
The following icons will be used throughout the manual:
!
Warning! A warning indicates severe damage to the user and/or product may occur when a
procedure is not carried out as described.
!
Caution! A caution sign indicates problems may occur if a procedure is not carried out as
described. It may also serve as a reminder to the user.
2. Product specifications
2.1. Product features
• Traction battery
• Lithium Iron Phosphate (LiFePO4)
- Safe lithium technology
- Superior abuse tolerance
• Integrated BMS (Batterie-Managementsystem)
• Glass fiber reinforced plastic (GRFP) Casing, Aluminum / PE sandwich side panels
• Terminals for 2 x 95mm2 wire connection per terminal
• Integrated fuse, 32V / 300A
• 3C continuous discharge (300A)
• CANopen interface for battery monitoring
• Battery monitoring / History Storage
• Adaptive cell balancing
• Serial string equalization
• Serial string connection up to 1150V DC
• Battery Disconnect device, Relay, Latching relay (bi-stable)
• Battery Disconnect device, CAN Controlled
2.2. General product specifications
Product name: SB12V100E-ZC
Producer: Super B b.v.
Battery type: Lithium Iron Phosphate (LiFePO4)
Product Lifespan: +/-5 to 10 years or 1000-2000 cycles at 1C charge / discharge
or 8000 cycles at C3 charge / discharge*
*The lifespan value given above is an indication. Battery lifespan depends strongly on the
applied charging and discharging loads. For more information on the lifespan of the battery,
appendix II may be consulted.

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2.3. Technical specifications
Mass: 18.5 kg +/- 0.250 kg
Ingress protection rating IP53
2.3.1. Battery designation
Battery designation: 9586 100 9305 0
2.3.2. Electrical properties
Nominal voltage 13.2V DC
Charge method CCCV
Maximum end of charge voltage 15.4V
End of charge voltage for endurance (cycle life) 14.4V DC
Charge current 100A (1C)
Charge current for endurance (cycle life) 33.3A (C/3)
End-of-discharge voltage 8V DC
End-of-discharge voltage for endurance (cycle life) 10V DC
Maximum serial string connection voltage 1150V DC
Discharge current 300A (3C)
Discharge current for endurance (cycle life) 33A (C/3)
Discharge pulse current (10 seconds) (external fuse) 800A (8C)
Discharge pulse current (60 second) (external fuse) 500A (5C)
Discharge performance at 20 °C (rated capacity) 100Ah / 1320Wh
Discharge performance at –20 °C (capacity) 65Ah / 858Wh
High rate discharge performance at 20 °C (capacity) 90Ah / 1188Wh
Short-circuit protection (fuse): 300A
Self-discharge: ± 10% per year
More information on the battery’s discharge performance and capacity may be found in
appendix III.

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2.3.3. Dimensions
Height (H): 313.00 / 314.00 mm
Width (W): 413.50 / 414.50 mm
Thickness (T): 225.00 / 226.00 mm
313.0
314.0
225.0
226.0
413.5
414.5
2.4. Environmental conditions
!
Warning! The Li-Ion Battery may only be used in conditions specified in this manual.
Exposing the battery to conditions outside the specified boundaries may lead to serious
damage to the product and/or the user.
Use the battery in a dry, clean, dust free, well ventilated space. Do not expose the battery to
fire or water or solvents.
When the batteries are placed in an enclosed environment without air circulation, it’s advised
to provide 2 ventilation holes of 100mm x 100mm each. This helps to prevent the heath built-up.

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Operating temperature range (Charge) (1) -20°C to +60°C
Operating temperature range (Discharge) -20°C to +60°C
Storage temperature range -20°C to +60°C
Relative humidity Between 5 and 85 %, non-condensing
Placement angle (continuously) 90 degrees
Vibrations and shocks As described in UN38.3 and IEC 6228
(1) Fast charging at temperatures lower then 0°C or higher then 45°C can reduce battery life. For maximum battery life a charge temperature
range of 0°C to +45°C is advised. Consult your reseller or Super B for charge rate recommendations for your application.
2.5. Required tools
• M13 Hexagon socket wrench
• Fuse TORX key
2.6. Components
1
2 3 4 5 6 7 8 9 10 11
2.6.1. List of components
1. (1) Super B SB12V100E-ZC Battery
2. (4x) M8 Bolt
3. (6x) M8 Spring washer
4. (6x) M8 Plain washer
5. (2x) M8 Nut
6. (2x) Mega Fuse 32V/300A
7. (1x) Dummy Fuse
8. (1x) Phoenix plug 4
9. (1x) Phoenix plug 7
10. (2x) Terminal cover, Red
11. (2x) Terminal cover, Black

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2.7. Connections, indicators and battery controls
1 2 3 4 5 6 7
1 2 3 4
1
2
3
64 5
7
8
1. Con 1 (I/O Connection 4; Phoenix FRONT-MC 1,5/4-STF-3,81 1850877)
2. Con 2 (I/O Connection 7; Phoenix FRONT-MC 1,5/7-STF-3,81 1850903)
3. Con 3 (CANopen; 5-pin “micro” style connector)
4. Terminal - (2x 95mm2wire connection)
5. Fuse cover
6. Terminal + (2x 95mm2wire connection)
7. Reset button
8. Fuse connections

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2.7.1. Con1 (I/O Connection 4)
Pin1: +, OFF
Pin2: -, ON
Pin3: -, OFF
Pin4: +, ON
2.7.2. Con2 (I/O connection 7)
Pin1: V+ max 30 Volt
Pin2: AN_SOC (Analogue state of charge)
Pin3: Nc (Not connected)
Pin4: Rc, (Relay common contact)
Pin5: Rnc, (Relay normaly close contact)
Pin6: Rno, (Relay normaly open contact)
Pin7: GND, (Ground)
2.8. Peripheral equipment
2.8.1. Obligatory
In order for the Li-Ion battery to be used safely, an approved external switch off device
must be installed. This should either be a relay or latching relay (bi-stable) controlled by the
battery’s BMS or a relay or latching relay controlled by a remote switch (CAN controlled).
(see paragraph 4.4) Failure to install an external switch off device will void the warranty of
the Li-Ion battery.

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2.8.2. Optional
The Li-Ion battery can be used in combination with a number of (Super B) products:
Article name Article code
SB-LIR250 (relay) 9586 100 3106 0
SB-V23130C2021A412-TE (latching relay) 9586 100 3108 0
SB Terminator Resistor Female 9586 100 4001 0
SB Terminator Resistor Male 9586 100 4002 0
SB CAN Male-female Cable 0.6m 9586 100 3001 0
SB CAN Male-female Cable 1m 9586 100 3002 0
SB CAN Male-female Cable 2m 9586 100 3003 0
SB CAN Male-female Cable 5m 9586 100 3004 0
SB CAN Male-female Cable 10m 9586 100 3005 0
SB T-splitter 9586 100 3006 0
SB BiB LV48V350A 8718531360914 9586 100 3008 0
SB USB to Can 9586 100 3201 0
SB Monitor Software 9586 100 3201 0
Mounting bracket ZC casing 9586 300 0009 0
3. Safety guidelines and measures
3.1. General
!
Warning! Keep the battery away from fire, excessive heat, water, dust and contamination.
!
Corrosive! Do not touch the battery’s electrolyte after leakage. If contact occurs, flush with
(lukewarm) water and seek medical assistance immediately.
!
Warning! Do not disassemble, crush, or puncture the battery.
!
Warning! Keep the Li-Ion battery away from children.
!
Warning! Never touch the battery contacts or allow (conductive) objects to touch the contacts.
3.2. Installation
!
Warning! Never use the Li-Ion battery without a properly installed Battery Disconnect device,
controlled by either the Li-Ion battery or a Battery communication Interface (SB BCI-C1).

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3.3. Use
!
Warning! Do not overcharge the Li-Ion battery.
!
Warning! Never short circuit the battery.
3.4. Disposal
Dispose of the battery in accordance with local, state and federal laws and
regulations. Batteries may be returned to the manufacturer. Do not mix with other
(industrial) waste.
3.5. Safety symbols and markings on product
A number of safety symbols and markings can be found on the product. These markings are
displayed below. Never remove these markings!
Symbol Description
Keep the Li-Ion battery upright. Never tilt the battery more than
90 degrees.
LI-ION
Dispose of the Li-Ion battery in accordance with local, state and
federal laws and regulations. Batteries may be returned to the
manufacturer. Do not mix with other (industrial) waste.
This product, or sections of this product can be recycled.
LI-ION

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4. Installation
4.1. General information
!
Warning! Do not disassemble, crush, or puncture the Li-Ion battery.
!
Warning! Never install or use a damaged battery.
When connecting several batteries in series or parallel, always use batteries of the same
brand, type, age, capacity and state of charge.
The Li-Ion battery is one on one interchangeable with AGM/GEL lead acid batteries.
4.2. Unpacking
Check the battery for damage after unpacking. If the battery is damaged, contact your
reseller or Super B. Do not install or use the battery if it is damaged!
4.3. Preparing the battery for use
4.3.1. Placement of the battery
Before it is used, the Li-Ion battery must be positioned in such a way that it will not move
around in its compartment during use. If necessary, the Li-Ion battery may be fixed in place
by means of Super B mounting brackets. The brackets can be screwed in place by means of
bolts or screws (See Figure 1).
Figure 1. Installing the Li-Ion battery using the Super B mounting brackets

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4.3.2. Placement and removal of a fuse
Before the Li-Ion battery can be used, either an internal fuse or a dummy fuse needs to be
installed into it. Two 48V/500A Mega fuses and one dummy fuse are supplied with the product.
Other fuses may only be used in the product when they are approved by Super B for this
application.
• Use an internal (Mega) fuse if a single battery is installed, if two batteries are installed in
series or if a number of batteries are installed parallel to one another. The discharge current
may not exceed 500A and the maximum voltage may not exceed 48V.
• Use a dummy fuse if three or more batteries are placed in series, if maximum discharge
current exceeds 500A or if the maximum voltage exceeds 48V.
!
Warning! Always use an external fuse with the appropriate value when a dummy fuse is used.
Use the following steps to place a Mega Fuse or a dummy fuse in the battery (Figure 2):
1. Turn off any device or charger the battery is connected to.
2. Turn off the external BMS (latching) relay or external BMS cut-off switch.
3. Disconnect the negative wire from the - pole of the battery (see paragraph 4.5.5. for the details).
4. Disconnect the positive wire from the + pole of the battery.
5. Unscrew the fuse cap using the fuse TORX key.
6. Unscrew the fuse contacts using the M13 wrench.
7. Press the reset button for 5 seconds.
8. Place the (new) fuse between the contacts, place washers and spring washers and tighten
the fuse contact points to 13Nm.
9. Fasten the fuse cap.
10. Proceed to the next paragraph to read the instructions on installing the battery in an electrical
circuit.
Figure 2. Install a fuse

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4.4. Connection wires
Use appropriate wire for the connection wires to ensure no overheating or unnecessary losses
occur. Consult the SAE-J378 or ISO 10133:2012 standards to determine the appropriate wire
properties. Use appropriate fuses matching the wires and load. See appendix IV for more details.
4.5. Installing the battery in an electrical circuit
!
Warning! Never use the Li-Ion battery without a properly installed Battery Disconnect device (relay or
latching relay) controlled by either the Li-Ion battery or a Battery communication Interface (SB BCI-C1)
!
Warning! Install the appropriate fuse before connecting the battery to other devices (see
paragraph 4.3.2). Use an appropriate external fuse if a dummy fuse is used.
4.5.1. Installing a Battery Disconnect device,
An external Battery Disconnect device can be installed between the + or - terminal of the battery
and the load. This Battery Disconnect device can be controlled in one of two ways:
• Connect a latching relay or a normal relay to the battery’s internal driver.
• Connect a latching relay or a normal relay to a remote switch. If applicable, consult the manual
of the remote switch for the appropriate installation instructions.
Connecting a latching relay to the battery:
1. When using a latching relay, connect it to Con 1 (I/O Connection 4) as displayed in Figure 3.
The internal driver controls both high and low side.
The output of Con 1 can be found in Table 1.
X2
+
+
Fuse
BT1
Battery
ChargerAC
+-
Minus (-)
Plus (+)
Load
AB
J2_IO
J3_CAN
J1_BREL
X1
_
_
+,off-,on+,on-,off
1234
Load Battery
Con1
Figure 3. Connect a latching relay as Battery Disconnect device

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Con 1 output (12V DC)
Continuous 2,7A
100ms pulse 15 A
Table 1.
Connecting a normal relay as Battery Disconnect device:
!
Warning! Always connect the relay between the + or - terminal of the battery and the load.
1. When using a normal relay, connect it to Con 2 (I/O Connection 7), Pin 4 (Rc) and Pin 5 (Rnc)
as displayed in Figure 4.
Pin 4
V max 250V DC
A max 5A
J2_IO
J3_CAN
J1_BREL
X1
X2
BT1
Battery
Charger
AC
+
-
FUSE
Plus
Minus
K1
Rc
123 4
Rnc
Load Battery
Con2
567
Fuse 5A
GND
Minus (-)
Plus (+)
Load
5A
Rc
Rnc
+
+
_
_
Fuse
A1A2
Figure 4. Connect a normal relay as Battery Disconnect device.
4.5.2. Connecting CANopen interface
To use the battery monitoring software, the CAN bus of the Li-Ion battery (CON 3) needs to be
connected to the computer on which the monitoring software is installed.
More information on the CANopen bus can be found at the CiA website: www.can-cia.org.
The required documentation can be found in the following CiA documents: (or in a future
version of these documents.)
• CiA 301
• CiA 303_1 V1.8.0; Sections 5 (AC and DC parameters) and 7.2: (5-pin “micro” style connector)

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CAN Bus network topology
The CAN Bus must be used in a bus network topology (see Figure 5 and Figure 6). Do not
use a ring- or a star topology. The CAN specifications restrict the Bus length/Bus speed.
Displayed in Table 2 is an overview of these restrictions.
J1_MASTER
J2_SLAVE
ON
OFF
RESET
SW_SUP
J2_IO
J3_CAN
J1_BREL
J2_IO
J3_CAN
J1_BREL
J2_IO
J3_CAN
J1_BREL
J2_IO
J3_CAN
J1_BREL
CAN_Term _Female
BAT_MIN
BAT_PLUS
LOAD_MIN
LOAD_PLUS
Battery
Interface Box
CA
N_Term _Male
USBCAN
BSU BSU
X1
X2
BT11
X1
X2
BT12
X1
X2
BT13
X1
X2
BT14
Minus (-
)
Plus (+)
PC Battery Monitor
+
- -
+
USB
+
+
_
_
Fuse
+
+
_
_
Fuse
+
+
_
_
Fuse
+
+
_
_
Fuse
Figure 5. CAN Bus network topology
Bitrate Buslength (L) Max. stublength (S) Accumulated stub length
250 kbit/s 250 m 11 m 55 m
Table 2. CAN bus speed
The default speed of the Can BUS is 250 kbit/s.
A high speed bus requires termination at the two ends of the bus. The CAN to USB converter
can either be connected at one end of the bus (with termination) or in the middle of the bus
with no termination; termination should then be placed at the endnodes of the bus line.
Termination Resistors
Use termination resistors at the end nodes to impede reflections on the line. The value of this
resistor should be +/- 120 ohms. More information on termination resistors can be found in
CiA document 303_1 V1.8.0, section 5.

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CAN bus power
Due to the galvanic separation between the battery monitoring hardware and the battery, an
external power supply is needed for the CAN bus. The CAN bus can be powered by either
the SB-BCI. If the SB-BCI cannot be used, the CAN bus can be powered through Con 2 (I/O
Connection 7). This situation may occur when a USB-to CAN interface is directly connected
to the battery (Figure 6).
1. Connect Pin 1 of Con2 to the + terminal of the battery.
2. Connect Pin 7 of Con2 to the - terminal of the battery.
J2_IO
J3_CAN
J1_BREL
X1
X2
BT11
FUSE
USBCAN
BSUBSU
CAN_Term_Female
CAN_Term_Male
V+
1234
GND
V+ Battery
Con2
567
Fuse 5A
V- Battery
5A
V+
GND
+
+
_
_
Fuse
USB
Figure 6. Use Con2 to power the CAN bus
4.5.3. Connecting the battery to the load
!
Warning! Ensure you have completed all the previous steps described in chapter 4 before
connecting the battery to the load.
1. Slide the terminal covers over the connection wires.
2. Connect the + terminal of the battery to the - or A2 terminal of the relay (Figure 7).
3. Connect the load or charger to the + or A1 terminal of the relay.
4. Connect the - terminal of the battery. Do not connect the - terminal first as this may lead to
short circuits (Figure 7).
5. Ensure both contacts are tightened to 20Nm.
6. Place the terminal covers over the terminals (Figure 8).

20
2
1
(Latching) Relay
(Load/Charger)
Figure 7. Connecting the battery to the load
(Latching) Relay
Load/Charger
Figure 8. Securing the terminal covers
J2_IO
J3_CAN
J1_BREL
X1
X2
BT11
Minus (-)
Plus (+)
Load
AB
+
+
_
_
Fuse
Figure 9. Connecting the battery to the load