VOLTA evoTractionBattery User manual

evoTractionBatteryevoTractionBattery
TM_evoTractionBattery_1.4_en

ecovolta AG
Gersauerstrasse 71
6440 Brunnen
Switzerland
[phone]
[e-mail]
eco-volta.com
This document may not be reproduced without the written permission of ecovolta AG neither
reproduced nor otherwise reused.
© 2023 ecovolta AG. All rights reserved. Data without guarantee. Subject to change without notice.
2TM_evoTractionBattery_1.4_en

Table of contents
Table of contents
1 About this content...........................................................................................................................................1
1.1 Validity......................................................................................................................................................1
1.2 Target group...........................................................................................................................................1
1.3 Content and purpose...........................................................................................................................1
1.4 Additional information........................................................................................................................2
1.5 Warnings and categories................................................................................................................... 3
2 Basic safety information and warnings.................................................................................................... 4
2.1 Safety first!.............................................................................................................................................4
2.2 Proper use.............................................................................................................................................. 4
2.3 Generally valid safety information..................................................................................................4
2.4 Fire protection measures...................................................................................................................8
2.5 Environmental protection................................................................................................................10
3 Product description....................................................................................................................................... 11
3.1 Overview............................................................................................................................................... 11
3.2 Scope of delivery................................................................................................................................13
3.3 Technical data..................................................................................................................................... 15
3.3.1 Battery type overview...................................................................................................... 15
3.3.2 General technical data......................................................................................................16
3.3.3 Battery type: eTB48-50-025 F......................................................................................17
3.3.4 Battery type: eTB48-100-05 F......................................................................................19
3.3.5 Battery type: eTB48-200-10 F......................................................................................21
3.3.6 Battery type: eTB48-300-15 F......................................................................................23
3.3.7 Battery type: eTB96-50-05 F........................................................................................ 25
3.3.8 Battery type: eTB96-100-10 F......................................................................................27
3.3.9 Battery type: eTB96-150-15 F......................................................................................29
3.3.10 Derating curve diagrams..................................................................................................31
3.3.11 PIN assignment of the CAN connections....................................................................38
3.3.12 Lithium Ion Battery............................................................................................................39
3.3.13 Materials................................................................................................................................40
3.4 Marking................................................................................................................................................. 41
4 Planning............................................................................................................................................................ 43
4.1 Notes on system integration......................................................................................................... 43
4.2 Connection options............................................................................................................................44
4.2.1 Standalone battery............................................................................................................ 44
4.2.2 Batteries in series connection........................................................................................45
4.2.3 Batteries in parallel connection.....................................................................................46
5 Installation and commissioning................................................................................................................ 47
5.1 Check installation requirements................................................................................................... 47
5.1.1 Requirements for stability...............................................................................................47
5.1.2 Requirements for protection against damage.......................................................... 47
5.1.3 Requirements for ease of operation and maintenance..........................................47
5.2 Install evoTractionBattery............................................................................................................... 48
5.3 Connecting the evoTractionBattery..............................................................................................49
5.3.1 Connect battery terminals and equipotential bonding...........................................49
5.3.2 Connect charger..................................................................................................................50
5.3.3 Connect external components....................................................................................... 51
5.3.4 Wire system for charging the vehicle battery at a charging station...................53
5.4 Switch on and switch off the battery......................................................................................... 54
5.4.1 Battery button displays....................................................................................................54
5.4.2 Precondition for continuous operation........................................................................54
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Table of contents
5.4.3 Switching the battery on and off at the battery button or at an external
button.....................................................................................................................................55
5.4.4 Switch battery on and off via 12V_ON signal.......................................................... 57
5.4.5 Switch battery on and off via CAN-ENABLE signal................................................. 58
5.4.6 Structure of CAN messages............................................................................................60
5.5 evoTractionBattery charging...........................................................................................................63
5.5.1 Charging the vehicle battery at the charging station..............................................63
5.5.2 Charging the vehicle battery on a built-in charger.................................................. 63
5.5.3 Charging the vehicle battery on an external charger.............................................. 64
5.5.4 Loading times...................................................................................................................... 64
5.6 Putting the vehicle into operation................................................................................................65
6 Check system status and troubleshoot..................................................................................................66
6.1 Controls and displays....................................................................................................................... 66
6.2 Read out system values..................................................................................................................66
6.3 LED indicators interpret...................................................................................................................67
6.4 Detect and fix errors.........................................................................................................................67
7 Maintenance....................................................................................................................................................69
7.1 Maintain and service.........................................................................................................................69
7.2 Replace evoTractionBattery............................................................................................................ 70
7.3 Power/signal cable replacement.................................................................................................. 72
7.4 Accessories and spare parts.......................................................................................................... 72
7.5 Service, maintenance and support...............................................................................................72
8 Disposal and recycling..................................................................................................................................73
II TM_evoTractionBattery_1.4_en

1 About this content
1 About this content
Below is important information about the content.
1.1 Validity
The content is valid for the following products:
•eTB48-50-025 F
•eTB96-50-05 F
•eTB48-100-05 F
•eTB96-100-10 F
•eTB48-200-10 F
•eTB96-150-15 F
•eTB48-300-15 F
1.2 Target group
Depending on the target group, there are different activities that may be performed.
Target audience Prerequisite Product knowledge
Operator •End user of a system in which the
product is installed (e.g. vehicle
driver, equipment operator, etc.)
•No special knowledge required
•Technical data and intended use
of the product
•Sources of danger and safety de-
vices of the product
•Correct behavior in the event of
malfunctions
Qualified
personnel
•see “Operator
•Electrotechnical training/further
training
•General knowledge of electronics
and battery circuitry
•see “Operator
•In-depth knowledge of the user
interface and its functions (para-
meterization)
•Knowledge of the application ar-
eas and processing options
Specialized per-
sonnel
•see “Operators” and “Qualified
personnel
•Electrotechnical education/fur-
ther training
•In-depth knowledge of battery
wiring
•For systems from 60 V DC: High
voltage course
•English language skills (written
and spoken)
•see “Operators ”and “Qualified
personnel
•Reading and interpreting elec-
trical diagrams, I/O list and BMS
parameters
•In-depth knowledge of PC hard-
ware, operating system (Win-
dows), peripherals and applica-
tions of the product.
•In-depth knowledge of applica-
tions
•Systematic procedure for trou-
bleshooting and fault diagnosis
•Training for fire-fighting in the
case of Li-ion batteries
1.3 Content and purpose
This information is limited to the assembly, installation, setup and basic operation of the product.
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1 About this content
1.4 Additional information
In the download area under eco-volta Download additional information can be found such as:
•Quick Guide (QG)
•Warranty Terms and Conditions (WT)
•Consumer Notes (CN)
How do you find the information?
1. Open link.
2. Select language.
3. Select the desired category (product name).
4. If necessary select document type.
✓The requested documents will be displayed and can be downloaded
2TM_evoTractionBattery_1.4_en

1 About this content
1.5 Warnings and categories
Warnings must be observed and are therefore specially marked. They contain information on
potential damage or injuries so that accidents and damage can be prevented.
DANGER
Indicates an immediate threat which could lead to serious injuries or death.
WARNING
Indicates a potentially dangerous situation which could lead to serious injuries or death.
CAUTION
Indicates a potentially dangerous situation which could lead to minor injuries.
Safety instruction
This warning concerns the proper way to handle the product. If ignored, it could lead to damage
or loss.
INFORMATION
Contains additional information on the product to help users better understand and operate the
product.
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2 Basic safety information and warnings
2 Basic safety information and warnings
This section contains important basic safety information and warnings that must be observed when
handling the product.
2.1 Safety first!
Before working on or with the product: read this operating manual through completely. If not
observed, there is the risk of property damage as well as injury and risk to life.
2.2 Proper use
This product is intended exclusively for the use specified in Kapitel "Gerät kennenlernen" is
described. Any use beyond this is considered improper, and for any damage resulting from this,
theecovolta AG not. The user/operator bears sole responsibility for all the risks associated with
improper use.
2.3 Generally valid safety information
Ensuring employee qualification
Make sure that anyone working on or with the battery has the required personnel qualifications for
their job, see "Target group" page 1.
Safety instructions for handling the battery
The following personal protective equipment must be worn when using the product:
Eye protection
Hand protection
Foot protection
Before working with the battery: Ensure that the battery is in perfect condition and has no worrying
characteristics. Worrying characteristics include:
•Cracks or breaks in the battery housing
•Mechanical damage to the battery housing
•Malfunction
•Other anomalies
If the battery has any characteristics of concern, do not install or use it.
DANGER
Electric shock
Contact with live parts results in severe bodily injury or death.
•The batteries >60 V DC may only be sold to and the systems commissioned by trained
specialized personnel.
•The trained specialized personnel are responsible for safe installation of the system.
•The system in which the batteries are installed must contain insulation monitoring as a
safety component (already installed at the factory depending on the configuration).
•Work on live parts may only be carried out by specialized personnel.
•Work on the evoTractionBattery may only be performed when it is switched off.
•The user must not make any technical modifications to the evoTractionBattery.
•The evoTractionBattery must not be opened, disassembled or repaired by the user.
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2 Basic safety information and warnings
WARNING
Live parts
Contact with live parts can result in serious bodily injury or death.
•It must be ensured that no voltage is present before working on the electrical system.
•Work on the electrical system must only be carried out by qualified personnel.
•All connectors to the evoTractionBattery must be disconnected before starting work on the
electrical system.
WARNING
Electric shock due to improper wiring
Contact with live parts can result in serious bodily injury or death.
•The wiring of evoTractionBattery may only be performed by specialized personnel.
WARNING
Humidity
Electric shock
•The evoTractionBattery must be protected against water ingress.
•The installation location must be protected from direct water contact.
WARNING
Lithium-ion batteries can explode or burst explosively and toxic gases can escape.
Improper handling of lithium-ion batteries can lead to fires and explosions.
•The lithium-ion batteries in the evoTractionBattery must be protected from fire and/or high
temperatures.
•Do not open or damage the lithium-ion batteries in the evoTractionBattery.
•Do not short-circuit the lithium-ion batteries in the evoTractionBattery.
CAUTION
Lithium-ion batteries can explode or burst explosively and toxic gases can escape.
Improper handling of lithium-ion batteries can lead to fires and explosions.
•Call fire department.
•Protect airways.
•If possible, remove evoTractionBattery from the source of the fire.
•Use suitable extinguishing agent.
CAUTION
Heavy battery over 25 kg.
Risk of physical injury during lifting.
•Only lift the battery in pairs.
CAUTION
Triggering of the bursting membrane.
Danger of hearing damage due to noise when equalizing pressure.
When the bursting membrane is triggered, put on hearing protection.
CAUTION
Electric shock due to connected devices
Contact with live parts can lead to minor physical injuries.
•The safety of the electrical system must be taken into account and ensured during the
planning stage.
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2 Basic safety information and warnings
Safety instruction
•The evoTractionBattery and its components must not be exposed directly to flames.
•The housing of the evoTractionBattery must not come into contact with acetone.
Safety instruction
The evoTractionBattery must be transported in accordance with ADR/RID. It is transported tied to
pallets, in a sturdy wooden box and with labelling in accordance with UN3480.
Insofar as applicable, the UN 38.3 test report has been handed over to the carrier.
Safety instruction
Battery housing that is vulnerable to impact.
Risk of damage in case of improper handling.
•Leave the battery in its original packaging until use.
•Transport the battery with care.
•Protect the battery from shocks.
•Do not pull or push the battery across the floor.
•Avoid mechanical stress, e.g. by stepping on the battery.
•Check the battery for damage after unpacking.
•Do not put a damaged battery into operation.
Safety instruction
The evoTractionBattery must not be used in the following areas of application:
•Nuclear Technology
•Medical Technology
•Aviation
•Submarine application
•Ex zone areas
•Critical infrastructures
Safety instruction
•The evoTractionBattery may only be charged within the temperature range described in the
technical data.
•The evoTractionBattery must not be used at an altitude above 3500 meters above sea level.
•The evoTractionBattery may only be charged with CAN bus-capable lithium-ion battery
chargers in CCCV mode (Constant Current - Constant Voltage).
Safety instruction
•Opening the evoTractionBattery is strictly prohibited.
•Opening the evoTractionBattery will void the warranty.
Safety instruction
•The HV network must be implemented potential-free.
•A galvanically isolated charger is required to charge the evoTractionBattery.
•Commissioning and maintenance of electrical systems may only be carried out by qualified
personnel.
Safety instruction
The user must provide a secondary protection mechanism for the evoTractionBattery.
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