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.
TM_evoTractionBattery_1.4_en 1

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.
TM_evoTractionBattery_1.4_en 3

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.
TM_evoTractionBattery_1.4_en 5

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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2 Basic safety information and warnings
Safety instruction
evoTractionBattery is stored and switched off
Possible damage to the evoTractionBattery due to deep discharge
•The storage of the evoTractionBattery under -10 °C and above 45 °C (max. 3 months) or
above 24 °C can lead to damage to the cell chemistry.
•The humidity during storage must be within 5-95 % .
•The evoTractionBattery must be protected against mechanical influences.
•All connections not occupied with connectors must be sealed using dummy plugs in order to
maintain the IP protection class.
•Before storing the evoTractionBattery, a complete charging cycle has to be run through at
least 90 % of the initial battery capacity. Discharge to 30 % before storage.
•If the storage period exceeds 6 months, a complete charging cycle must be run every 6
months, at least until 90 % of the initial battery capacity. Discharge to 30 % before storage
again.
Safety instruction
Damage to the evoTractionBattery due to water ingress
Water ingress will damage the evoTractionBattery.
•The evoTractionBattery must be installed so that it is protected from water and humidity.
•The evoTractionBattery must not be cleaned with a high-pressure cleaner.
Safety instruction
•The product must only be assembled and installed by a specialist see “Ensuring employee
qualification” see "Ensuring employee qualification".
•The installation may only be carried out in locations that meet the requirements of ecovolta
AG meet the specified climatic and technical conditions.
•The evoTractionBattery is preferably installed and operated horizontally on the stand.
•If the battery is to be installed lying on one side or standing on one end face: suitable devices
should prevent the battery housing from being damaged due to specific areas of pressure.
•The battery must not be installed upside down.
•ecovolta AG is not liable for damage caused by improper handling or faulty installation.
Safety instruction
The warranty is voided if the evoTractionBattery is opened.
INFORMATION
In case of technical problems, please contact the regional contact point of ecovolta AG.
INFORMATION
The electromagnetic compatibility of the entire system must be checked.
INFORMATION
This Technical Manual must be kept in the vicinity of the evoTractionBattery.
TM_evoTractionBattery_1.4_en 7

2 Basic safety information and warnings
2.4 Fire protection measures
WARNING
Organic cell contents are flammable above 125 °C.
In the event of overheating or fire, harmful gases will escape and the battery may explode.
Harmful gases:
•Hydrogen fluoride
•Carbon monoxide
•Carbon dioxide
Avoid causes of overheating:
•External heat exposure
•Exceeding the maximum permissible load
•Overload
•Short circuit
•Mechanical damage
Preventive measures
•Observe the storage instructions for Li-ion batteries.
•Inform the fire department about the storage locations of the Li-ion batteries and about
parking locations of the vehicles or machines.
•Mark escape and rescue routes.
•Have suitable extinguishing agent ready on site:
°Water
°Water with extinguishing additives
°Gel Extinguishing Agent
Safety instruction
The following extinguishing agents are not suitable and must not be used:
•ABC or BC powder
•Metal burning powder
•Carbon dioxide
Fire fighting measures
•If possible, remove the batteries from hazardous areas.
•Exit the vehicle.
•Alert the fire department with the indication of a burning Li-Ion battery.
•Do not expose yourself to the personal risk of endangering yourself.
•Only take your own measures if you are sufficiently practiced in doing so.
•Wear the appropriate personal protective equipment when fighting fires:
°Self-contained breathing apparatus according to NIOSH/MSHA
°Protective clothing
°Hand protection
•Keep people away from the hazardous area who are unprotected and not required for hazard
prevention.
•Fight the fire with suitable extinguishing agent. See: "Preventive measures".
•Observe the following minimum distances when deleting:
°With portable and mobile fire extinguishers with spray jet:
At least 1 meter
°For wall hydrants with spray jet (Euro nozzle):
At least 3 meters
°For wall hydrants with full jet:
At least 5 meters
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2 Basic safety information and warnings
•In case of clear smoke development or gas release:
°Leave the room or the hazardous area immediately.
°Ensure that there is adequate ventilation.
Fire watch
Safety instruction
Batteries can reignite even after a long time.
Store the batteries under water after extinguishing them:
•in a sufficiently large water basin
•in a general average container
When the extinguished battery must be moved to another location for fire watch:
•Contact the manufacturer for information on transport regulations.
•Obtain a transport permit from the appropriate authority.
•Have the battery transported by a specialized company.
TM_evoTractionBattery_1.4_en 9

2 Basic safety information and warnings
2.5 Environmental protection
The products of theecovolta AG are designed with eco-design in mind to minimize their impact on
the environment. The following features are considered standard in the design of the products:
•The products of the ecovolta AG are made of high quality materials to maximize the life of
their.
•The product design allows the separation of the different materials for reprocessing and
efficient recycling.
•The ecovolta AG is always working to further develop its products and continuously reduce
their environmental impact.
The products of the ecovolta AG serve to use energy more efficiently and thereby reduce everyday
environmental pollution. Theecovolta AG tries to keep the impact on people and the environment
low throughout the product cycle and to return as much as possible to the material cycle. It is
important that the user handles all products with care and uses them efficiently.
For information on return and disposal of the products see "Disposal and recycling".
10 TM_evoTractionBattery_1.4_en

3 Product description
3 Product description
This section contains information on the product.
3.1 Overview
In which vehicles may the evoTractionBattery be installed?
The evoTractionBattery is intended for installation in the vehicles listed below.
NOTE
For some applications, additional safety equipment and a respective assessment may be
necessary.
•Class L vehicles (two-, three- and light four-wheeled motor vehicles)
according to Directive 2002/24/EC and EU Regulation No. 168/2013
•Vehicles in categories M1 and M1G (at least four-wheeled vehicles for passenger transport
with a maximum of eight seats plus the driver's seat)
according to Directive 2007/46/EC, Annex II
•Vehicles of categories N1 and N1G (at least four-wheeled vehicles for the carriage of goods
and special purpose vehicles up to 3.5 t)
according to Directive 2007/46/EC, Annex II
•Class T vehicles (wheeled agricultural or forestry tractors)
according to Directive 2003/37/EC, Annex II
•Prototypes of vehicles for operation on the road (for the purpose of conducting a test
program).
according to Directive 2007/46/EC, Article 2, Section 4, letter b
•Construction site vehicles and self-propelled machinery (for use principally on construction
sites, in quarries or at airports, and vehicles used for work other than the carriage of
passengers or goods) in accordance with Directive 2007/46/EC, Article 2, Section 3, letters a
and c
•Class C vehicles (tractors on tracks or a combination of wheels and tracks).
according to Regulation (EU) No. 167/2013
•Watercraft (recreational boats and personal watercraft)
according to Directive 2013/53/EU
Can the evoTractionBattery also be used for other applications?
The evoTractionBattery may expressly be used for other applications only after written approval by
the manufacturer.
Which use is contrary to the intended use?
The battery is considered to be used contrary to its intended purpose:
•The use of the battery for purposes other than those specified.
•Any action that deviates from the instructions given.
•The use of the battery in disregard of the technical data.
•Any technical modification to the battery.
TM_evoTractionBattery_1.4_en 11

3 Product description
How is the evoTractionBattery constructed?
The evoTractionBattery is structured as follows:
Figure No. Meaning
1 Carrying handles
2 Battery pol (+)
3 Battery pol (-)
4 Battery Management System (BMS)
5 Battery button (on/off)
6 CAN OUT connection
7 Connection EXT. SIGN.
8 CAN IN connection
9 Berst membrane
10 Ground cable connection (potential equal-
ization)
11 Lithium-ion battery cells
How does the evoTractionBattery work?
The evoTractionBattery is equipped with lithium-ion battery cells that are charged and discharged
via the built-in Battery Management System (BMS).
The Battery Management System (BMS) is delivered from the factory with a standard configuration.
Special configurations must be specified when ordering.
About the function of the bursting membrane
The bursting membrane monitors the internal pressure of the
battery and opens in the event of overpressure to prevent the
battery housing from bursting.
Overpressure can be caused by the following events, for example:
•Extreme air pressure differences in the environment
•Heat development due to permanent overload
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3 Product description
3.2 Scope of delivery
Standard scope of delivery
The scope of delivery consists of:
1 evoTractionBattery
2 Original operating instructions
NOTE
This operating manual is an integral part of the product and is inseparable from the product
If the product is passed onto other owners, then the operating manual also has to be passed
on.
The operating instructions can also be downloaded online. Use the QR code on the type label
for this purpose.
Optional scope of delivery
The delivery contains additional separately packed components depending on the order:
1 Distributor box incl. CAN cable and battery button
2 Display
3 PCAN-Cable
4 Cable with Amphenol connector
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3 Product description
Additionally required components
INFORMATION
Depending on regional legal regulation, it may be necessary to install additional suitable protective
devices. Examples:
•Emergency stop for redundant protection of the high-voltage relay (highest priority)
•Additional external safeguarding on both poles
•High current distributor
•Housing circuit breaker (GSS)
•Interlock circle
•High-voltage relay
It is the customer’s responsibility to adhere to local regulations.
14 TM_evoTractionBattery_1.4_en

3 Product description
3.3 Technical data
3.3.1 Battery type overview
There are the following types of batteries:
eTB48-50-025 F eTB48-100-05 F eTB48-200-10 F eTB48-300-15 F
48 V
2.5 kWh
48 V
5.0 kWh
48 V
10.0 kWh
48 V
15.0 kWh
For general technical data, see:
"General technical data"
For product-specific technical data, see:
"Battery type:
eTB48-50-025 F"
"Battery type:
eTB48-100-05 F"
"Battery type:
eTB48-200-10 F"
"Battery type:
eTB48-300-15 F"
eTB96-50-05 F eTB96-100-10 F eTB96-150-15 F
96 V
5.0 kWh
96 V
10.0 kWh
96 V
15.0 kWh
For general technical data, see:
"General technical data"
For product-specific technical data, see:
"Battery type:
eTB96-50-05 F"
"Battery type:
eTB96-100-10 F"
"Battery type:
eTB96-150-15 F"
TM_evoTractionBattery_1.4_en 15

3 Product description
3.3.2 General technical data
The following technical data apply equally to all battery types:
Environmental conditions
Ambient temperature during charging
*)
-10 °C...+50 °C
Ambient temperature during dis-
charge
-25 °C...+60 °C
Ambient temperature during storage Up to 3 months: -10 °C...+45 °C
From 3 months: -10...+24 °C
Relative humidity max. 95 %
Pollution level PD2
*) Charging below -10 °C is not possible; at -10...0 °C only with 0.1 C.
Control
Communication CAN bus
CAN-In: SACC-DSI-M12FS- 12CON-M16 SH
Phoenix Contact Article no: 1441956
Signals: CAN_extern, CAN_intern, 12V Enable, Interlock,
HV Enable
CAN-Out: SACC-DSI-M12FS- 12CON-M16 SH Phoenix
Contact Article no: 1441956
Signals: CAN_extern, CAN_intern, 12V Enable, Interlock,
HV Enable
CAN bus connection
External Signals: SACC-DSI-M12FS- 12CON-M16 SH
Phoenix Contact Article no: 1441956
Signals: Display, LED, On Switch external, IEC 62196
charge modes CC/CP, Charge Plug Actuator Control, Vehi-
cle Unlock Button
CAN properties SOC (State of Charge)
Cell voltage
Battery voltage
Battery temperature
Battery power
General status
etc.
Baud rate 500 kbit/s
Security
Battery Management System (BMS) SIL2-Level
Balancing passive
Interlock HV connector monitoring
EMERGENCY OFF
Safety functions All pole disconnection
Over and under temperature shutdown
Over- and undervoltage shutdown
Overcurrent shutdown
16 TM_evoTractionBattery_1.4_en