Superb SB12V160E-ZC User manual

Manual
LITHIUM BATTERY
SB12V160E-ZC
12.9V/160Ah
Lithium Iron Phosphate
Version
June 2018

2
User Manual SB12V160E-ZC Lithium Iron Phosphate
battery
Dear customer,
This is your lightweight Super B SB12V160E-ZC traction Li-ion battery. A high performance
Li-ion battery with only 1/3 of the size of a conventional lead acid battery. The Li-ion battery is
designed to replace the much heavier 250 to 320 Ah lead-acid battery.
This manual contains all the information necessary to install, use and maintain the Li-ion
battery. We kindly ask you to read this manual carefully before using the product. In this
manual, the Super B SB12V160E-ZC Li-ion 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.
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 Li-ion battery for
any other purpose will be considered improper use and will void the warranty of the product.
Super B 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.
During the use of the product, user safety should always be ensured, so installers, users,
service personnel and third parties can safely use the Li-ion battery. This is the original
manual, keep it in a safe location! Please consult www.super-b.com for the latest version of
all manuals.
Copyright© Super B 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

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Be in charge Super B
For more information, or to order documents, contact:
Super B
Expolaan 50
7556 BE Hengelo (Ov) The Netherlands
Tel: [phone]
E-mail: [e-mail]
www: www.super-b.com
The Netherlands
Tel: [phone] (support)
E-mail: [e-mail]
www: www.super-b.com
Be in charge Super B

4
Table of content
1. Introduction 6
1.1. Product description 6
1.2. Glossary of Terminology 6
1.3. Used symbols 6
2. Product specifications 7
2.1. Product features 7
2.2. General product specifications 7
2.3. Technical specifications 7
2.3.1. Battery designation 8
2.3.2. Electrical properties (23°C) 8
2.3.3. Dimensions (±1mm) 8
2.4. Environmental conditions 9
2.4.1. Marine use 10
2.5. Required tools 10
2.6. Components 11
2.6.1. List of components 11
2.7. Connections, indicators and battery controls 11
2.7.1. Con1 (Output for BI-Stable Relay) 12
2.7.2. Con2 (I/O connection 7) 12
2.7.3. Con 3 (CANopen; 5-pin “micro” style connector) 13
2.8. Peripheral equipment 13
2.8.1. Obligatory 13
2.8.2. Optional Components 14
3. Safety guidelines and measures 15
3.1. General 15
3.2. Disposal 15
3.3. Safety symbols and markings on product 16
4. Installation 17
4.1. General information 17
4.2. Unpacking 17
4.3. Preparing the battery for use 17
4.3.1. Placement of the battery 17
4.3.2. Placement and removal of a fuse 18
4.4. Connection wires 19
4.5. Installing the mandatory Battery Disconnect device 19
4.5.1. Connecting a bi-stable relay to the Li-ion battery 19
4.5.2. Connecting a normal relay as Battery Disconnect device 20
4.5.3. Using the SB BIB (Battery Interface Box)
21

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4.5.4. Using the SB BCI-C1 (Battery Communication Interface) with a normal relay 21
4.6. Connecting the Li-ion battery to the load/charger 22
4.6.1. Connecting a single Li-ion battery to the load/charger with a bi-stable relay 22
4.6.2. Connecting a single Li-ion battery to the load/charger with a normal relay 23
4.6.3. Connecting Li-ion batteries in series. 25
4.6.4. Connecting Li-ion batteries in parallel 25
4.6.5. Connecting Li-ion batteries in series and parallel 26
4.7. CANopen interface 27
4.7.1. CAN Bus network topology 28
4.7.2. Termination Resistors 28
4.7.3. CAN balancing 29
5. Battery use 30
5.1. General information 30
5.2. Charging 30
5.2.1. Charging rate 30
5.2.2. Charging method 31
5.2.3. Battery balancing 33
5.2.4. Reading out the battery’s State of Charge (SoC) 33
5.3. Battery Monitoring Software 34
5.3.1. Battery History Recording 34
6. Inspection, cleaning and maintenance 35
6.1. General information 35
6.2. Inspection 35
6.3. Cleaning 35
7. Storage 36
8. Transportation 36
8.1. General 36
9. Disposal and recycling 37
9.1. General information 37
10. Troubleshooting 38
11. Warranty and liability 39
Appendix I. Declaration of Conformity 41
Appendix II. Performance Graphs 42
Appendix III. Conductor requirements 43

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1. Introduction
1.1. Product description
The SB12V160E-ZC is a Lithium Iron Phosphate rechargeable battery. The unique combination
of state-of-the art technology and smart software makes this Li-ion battery a robust, safe and
easy to use energy storage solution.
Compared to conventional lead acid batteries, the Li-ion battery offers an enormous weight
and space saving. It is very efficient, has extremely high performance and is maintenance
free.
Moreover, the Li-ion battery uses exceptionally safe Lithium Iron phosphate (LiFePO4)
technology. With its integrated battery management system the Li-ion battery is protected
from deep discharging, overcharging and overheating.
External disconnect device is required!
Potential applications of this Li-ion battery include: off grid power supply, marine power
supply, medium for (renewable) energy storage (traction) battery for vehicles.
In Appendix I, the Declaration of Conformity for the Li-ion battery is given.
1.2. Glossary of Terminology
BMS Battery Managent System
Charge cycle A period of use from fully charged, to fully discharged, and fully recharged
again.
Endurance Life-cycle The products maximum lifespan, achieved by following the guidelines
presented in this manual.
BCI Battery Communication Interface
LiFeP04 Lithium Iron Phosphate
SoC State of charge
CCCV Constant Current - Constant Voltage
DoD Depth of Discharge
Table 1. Glossary of terminology
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.

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Be in charge Super B
!
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 Li-ion technology
• Integrated BMS (Battery Management System), external interruption device needed
• Glass fiber reinforced plastic (GRFP) Casing, Aluminum / PE sandwich side panels
• Terminals for 2 x 95mm2wire connection per terminal
• Integrated fuse, 72V / 500A
• 3C continuous discharge (480A)
• Wired communication infteraface: CANopen
• Battery monitoring / History Storage
• Adaptive cell balancing
• Configurable in serial or parallel connection
• Output for bi-stable relay / latching relay
2.2. General product specifications
Product name SB12V160E-ZC
Producer Super B
Battery type Lithium Iron Phosphate (LiFePO4) / Traction battery
EAN number 8718531360570
Cycle life > 2000 (0.3C continuous discharge, DoD 100%)*
Table 2. General product specifications
*The cycle life value given above is an indication at 23°C. The Li-ion battery cycle life
depends strongly on temperature and the applied charging and discharging loads. For more
information on the cycle life of the Li-ion battery, appendix II may be consulted.
2.3. Technical specifications
Mass 26.9 kg +/- 0.250 kg
Ingress protection rating IP50
Table 3. Technical specifications

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2.3.1. Battery designation
Battery designation according to
EC61960 4IFpP85/170/245
Table 4. Battery
2.3.2. Electrical properties (23°C)
Open Circuit Voltage* 13.2V dc
Nominal voltage** 12.9V dc
Rated capacity 160Ah
Charge method CCCV
Charge voltage 14.3V...14.6V
End-of-discharge voltage 8V dc
Charge current Max 160A (1C)
Discharge current continuous 480A (3C)
Discharge current 10 seconds 800A (5C)
Table 5. Electrical properties (23 °C)
*Open Circuit Voltage at 50% SoC, no load
**Nominal voltage (V) at 50%, SoC, 0.2C discharge
More information on the Li-ion battery’s discharge performance and capacity may be found in
Appendix II.
2.3.3. Dimensions (±1mm)
Height (H) 314 mm
Width (W) 417 mm
Thickness (T) 227 mm
Table 6. Dimensions

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313.0
314.0
225.0
226.0
413.5
414.5
Figure 1. Dimensions
2.4. Environmental conditions
!
Warning! The Li-ion battery may only be used in conditions specified in this manual. Exposing
the Li-ion battery to conditions outside the specified boundaries may lead to serious damage
to the product and/or the user.
Use the Li-ion battery in a dry, clean, dust free, well ventilated space. Do not expose the Li-
ion battery to fire or water or solvents.
When the Li-ion battery is placed in an enclosed environment without air circulation, it is
advised to provide 2 ventilation holes of 100mm x 100mm each. This helps to prevent the heat
built-up.

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Recommended charge temperature range* 0°C to +45°C
Discharging operating temperature range -10°C to +55°C
Short term (<1 month) storage temperature range -20°C to +45°C
Long term (>1 month) storage temperature range -10°C to +20°C
Relative humidity 10-90%
Corrosion Salt-contaminated atmosphere up to
1 mg salt per m3of air, at all relevant
temperatures and humidity conditions.
Applicable to equipment located in open air
and made of material subject to corrosion.
Placement angle (continuously) Up right
Vibrations and shocks According UN38.3
Table 7. Environmental conditions
(1) Charging below 0 °C only with reduced charge current. This might result in degraded cycle life.
2.4.1. Marine use
Parameter Class Location
Temperature AMachinery spaces, control rooms, accommodation, bridge
Humidity BAll locations except as specified for location A
Vibration AOn bulkheads, beams, deck, bridge
EMC BAll locations including bridge and open deck
Table 8. Marine use
2.5. Required tools
• 13mm Hexagon socket wrench
• Torque wrench
• TORX key for fuse cover

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Be in charge Super B
2.6. Components
2 3 4 5 6 89 10 12 1311
1
Figure 2. Components
2.6.1. List of components
1. (1) Super B SB12V160E-ZC Battery
2. (4x) M8 Bolt
3. (6x) M8 Spring washer
4. (6x) M8 Plain washer
5. (2x) M8 Nut
6. (1x) Mega Fuse 72V/500A
7. (1x) Phoenix plug 7
8. (2x) Terminal cover, Red
9. (2x) Terminal cover, Black
10. (1x) Terminal protection cap, Red
11. (1x) Terminal protection cap, Black
12. (1x) USB stick (manual)
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
Figure 3. Connections, indicators and battery controls
32 4 5 6 8 10 11 12971

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1. Con 1 (Output for BI-Stable Relay; 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 95mm2 wire connection)
5. Fuse cover
6. Terminal + (2x 95mm2 wire connection)
7. Reset button
8. Fuse connections
2.7.1. Con1 (Output for BI-Stable Relay)
PIN # Output range (12V dc) Function
12.7A (continuous)
15A (100ms pulse) +, OFF
22.7A (continuous)
15A (100ms pulse) -, ON
32.7A (continuous)
15A (100ms pulse) -, OFF
42.7A (continuous)
15A (100ms pulse) +, ON
Table 9. Con1 (Output for BI-Stable Relay) Output Functions
2.7.2. Con2 (I/O connection 7)
PIN # Range Function
1 max 30 V dc + (Plus)
2 0-10 V dc AN_SOC (Analogue state of charge)
3 NA Nc (Not connected)
45A max
48V dc max Rc, (Relay common contact)
5Rnc, (Relay normaly close contact)
6 Rno, (Relay normaly open contact)
7GND, (Ground)
Table 10. (I/O connection 7)

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2.7.3. Con 3 (CANopen; 5-pin “micro” style connector)
PIN # Signal Description
1 CAN_SHLD Optional CAN Shield
2 CAN_V+
Optional CAN external positive supply
(dedicated for supply of transceiver and
optocouplers. if galvanic isolation of the bus
node applies)
3 CAN_GND Ground / 0V
4 CAN_H CAN_H bus line (dominant high)
5 CAN_L CAN_L bus line ( dominant low)
Table 11. Con 3 (CANopen; 5-pin “micro” style connector)
2.8. Peripheral equipment
2.8.1. Obligatory
In order for the Li-ion battery to be used safely, an 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). If an
external switch off device is not installed the warranty of the Li-ion battery will be void.

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2.8.2. Optional Components
The Li-ion battery can be used in combination with a number of (Super B) products:
Description Article name EAN code
SB-LIR250 (relay) SB-LIR250 (relay) 8718531361126
BI-Stable relay SB-V23130C2021A412-TE (latching relay) 8718531361010
Terminator Resistor Female SB CAN Terminator Resistor Female 8718531360808
Terminator Resistor Male SB CAN Terminator Resistor Male 8718531360815
CAN Male-female Cable 0.6m SB CAN Male-female Cable 0.6m 8718531360716
CAN Male-female Cable 1m SB CAN Male-female Cable 1m 8718531360723
CAN Male-female Cable 2m SB CAN Male-female Cable 2m 8718531360730
CAN Male-female Cable 5m SB CAN Male-female Cable 5m 8718531360747
CAN Male-female Cable 10m SB CAN Male-female Cable 10m 8718531360754
T-splitter SB CAN T-splitter 8718531360761
Battery Interface Box SB BiB LV48V350A 8718531360914
USB to CAN CAN Compact to USB 8718531361201
Battery monitor SB Monitor Software
Mounting bracket ZC casing SB Battery Bracket for SB12V100E-ZC and
SB12V160E-ZC 8718531360693
Battery Communication
Interface SB BCI-C1 8718531360884
Touch Display Touch Display 8718531361447
Touch Display + Cable Touch Display + Cable 8718531361447
BM01 Battery monitor SB BM01 12-24V 8718531361041
BM01 Battery monitor cable SB BM 01 Cable 2.5m 12-24V only 8718531361225
BM01 Battery monitor cable SB BM 01 Cable 5m 12-24V only 8718531361232
BM01 Battery monitor cable SB BM01 Cable 10m 12-24V only 8718531361249
Table 12. Optional components that can be used with the Li-ion battery

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Be in charge Super B
3. Safety guidelines and measures
3.1. General
• Do not short-circuit the Li-ion battery.
• Treat the Li-ion battery as described in this manual.
• Do not dismantle, crush, puncture, open or shred the Li-ion battery.
• Do not expose Li-ion battery to heat or fire. Avoid exporusre to direct sunlight.
• Do not remove the Li-ion battery from its original packaging until required for use.
• In the event of the Li-ion battery leaking, do not allow the liquid to come in contact with the
skin or eyes. If contact has been made, wash the affected area with copious amounts of
water and seek medical advice.
• Do not use any charger other than that specifically provided for use with the Li-ion battery.
• Observe the plus (+) and minus (–) marks on the Li-ion battery and equipment and ensure
correct use.
• Do not use any battery which is not designed for use with the Li-ion battery.
• Do not mix batteries of different manufacture, capacity, size or type within a device.
• Keep the Li-ion battery clean and dry.
• Secondary batteries need to be charged before use. Always use the correct charger and
refer this manual for proper charging instructions.
• Do not leave the Li-ion battery on prolonged charge when not in use.
• After extended periods of storage, it may be necessary to charge and discharge the Li-ion
battery several times to obtain maximum performance.
• Retain the original product documentation for future reference.
• Remove the Li-ion battery from the equipment when not in use.
!
Warning! Keep the Li-ion battery away from water, dust and contamination.
3.2. Disposal
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.

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3.3. Safety symbols and markings on product
Several safety symbols and markings can be found on the product. These markings are
displayed below. Never remove these markings!
The meanings of the symbols:
Shield eyes
Note operating instructions
Battery acid
Explosive gas
No smoking, no naked flames, no sparks
Keep away from children
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
Table 13. Safety symbols
14340_067_id_SUPB_Labels_Safety_30x70.indd 126-04-17 09:27

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Be in charge Super B
4. Installation
4.1. General information
!
Warning! Never install or use a damaged Li-ion battery.
!
Caution! Do not reverse connect the Li-ion battery(polarity)
When connecting several batteries in series or parallel, always use batteries of the same
brand, type, age, capacity and state of charge.
4.2. Unpacking
Check the Li-ion battery for damage after unpacking. If the Li-ion battery is damaged, contact
your reseller or Super B. Do not install or use the Li-ion battery if it is damaged!
4.3. Preparing the battery for use
!
Caution! Do not operate the Li-ion battery beyond published maximum specifications.
!
Caution! In case of an under-voltage shutdown, charge immediately.
!
Warning! Always remain within the limits indicated in chapter 2 during the use of the
Li-ion battery.
!
Caution! This Li-ion battery stores fault conditions internally, like excessive charge current or
deep discharge situations. Super B uses this information in the warranty process
!
Warning! Do not overcharge the Li-ion battery.
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 4).

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Figure 4. Installing the Li-ion battery using the Super B mounting brackets
4.3.2. Placement and removal of a fuse
Before the Li-ion battery can be used, the internal fuse needs to be installed into it. The 72V/500A
fuse is supplied with the Li-ion battery. Other fuses may only be used in the product when they
are approved by Super B for this application.
Use the following steps to (re)place the fuse in the Li-ion battery (Figure 5):
1. Disconnect the negative wire from the - pole of the Li-ion battery (see paragraph 4.5.5. for the details).
2. Disconnect the positive wire from the + pole of the Li-ion battery.
3. Unscrew the fuse cover using the fuse TORX key.
4. Unscrew the fuse contacts using a 13mm wrench.
5. Place the (new) fuse between the contacts, place washers and spring washers and tighten the fuse
contact points to 20Nm.
6. Fasten the fuse cover.
7. Proceed to the next paragraph to read the instructions on installing the Li-ion battery in an electrical
circuit.

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Be in charge Super B
Figure 5. Install a fuse
4.4. Connection wires
Use appropriate wire for the connection wires to ensure no overheating or unnecessary
losses occur. Use appropriate fuses matching the wires and load. See appendix III for more
details.
4.5. Installing the mandatory Battery Disconnect device
!
Warning! Always connect the relay between the + or - terminal of the battery and the load.
!
Warning! Never use the Li-ion battery without a properly installed Battery Disconnect device (relay
or latching relay).
An external Battery Disconnect device must be installed between the + or - terminal of the
Li-ion battery and the load. The protection of the Li-ion battery is possible by one of the
following ways:
1. Connect a bi-stable relay to the Li-ion battery’s Con1 output.
2. Connect a normal relay to the Li-ion battery’s Con2 (I/O connection 7) output.
3. By using the SB BIB (Battery Interface Box).
4. By using the SB BCI-C1 (Battery Communication Interface) and a normal relay.
4.5.1. Connecting a bi-stable relay to the Li-ion battery
1. When using a bi-stable relay connect it to Con1 output as displayed in Figure 6.
The Con1 output controls both the ON coil and the OFF coil of the bi-stable relay. The output
of Con1 can be found in Table 9.

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Load/Charger
Bi-stable Relay
Figure 6. Connect a bi-stable relay as Battery Disconnect device
4.5.2. Connecting a normal relay as Battery Disconnect device
1. When using a normal relay, connect it to Con 2 (I/O Connec tion 7), Pin 4 (Rc) and Pin 5 (Rnc)
as displayed in Figure 7.
Normal relay
Load/Charger
Figure 7. Connect a normal relay as Battery Disconnect device.