A123 Systems ALM 12V7 User's Guide
Contents
1. coos saavabsencasdveabanbecdeouacecese 4 1 Application 4 2 Configuration and Operation Terminology 5 1 Configuration Options ccccccccssccccssssccesssseccessseccceseeeeessseccessseecccseecesessecceesseecceseeeecsaaeeeeseeensaes 5 2 Charging Multiple MOdulesii csccsccscccsstsscsccaccacgssnssnceccacsacasiadsaceacacssadssadsncscdasssdaegacancssdassaesodacsads indeed 5 7 Discharging Battery Systems ccccsssscccceessssssseeeeecesessssseeecceseseesseeeeeeeeseesseeeeecessesssaseeeeeeenees 5 10 Integrated Module Protection ice retener rennen ann 5 11 Troubleshooting Charger Trips using Constant Voltage 6 1 Terminal Voltage Absent or 6 1 Battery Rapidly Depletes Energy between Charges eee nennen 6 3 Battery Current Disappears when eene nennen nennen 6 4 A Fuse Blows Frequently ccccccccssssssceccccessssseeeeecceeseesseeeeeeceeseesseeeeeeeeseeesaeeeeseseceeeaseeeeeeenees 6 4 Voltage Drops Abr ptly denen RSEN Y ER REN ERR GENERA COR AREE To Sae SERRE 6 5 Appendix A Terminology EE 1 THIS PAGE INTENTIONALLY LEFT BLANK Chapter 1 About this Document Overview This chapter includes the following sections e Overview on page 1 1 e Purpose of2. regulations that govern the transportation of hazardous materials also known as dangerous goods by air rail highway and water Regulations by Cell Battery Size Lithium ion batteries and cells are considered Class 9 which is one of nine classes of hazardous materials or dangerous goods defined in the UN US and other regulations As a class 9 material cells and batteries must meet UN testing and packaging requirements as well as shipping regulations The chart below provides a synopsis of the regulations now in effect for both the US and Internationally Table 2 1 Shipping and Packaging Regulations by Cell Battery Size Lithium Ion Shipping Special Packaging Regulation Cell Battery Classification Testing Markings 1 5 grams 8 0 Excepted 1 78 2 Yes Small grams Max ELC 5 0 grams 25 Class 9 T1 T88 Yes Medium US grams Max ELC gt 5 0 grams Class 9 T1 T8 Yes 9 Large gt 25 grams more than Max ELC 20 Wh 100 Excepted T1 T8 7 Yes Wh Max International Watt hours 220Wh 100 Class 9 T1 T8 9 Yes 8 Wh 1 Equivalent Lithium Content ELC in grams rated capacity Ah X 0 3 2 All cells and batteries must pass UN T1 T8 Tests 3 Cells and batteries must pass UN T1 T8 Tests and must be shipped as Class 9 hazardous materials unless transported by motor vehicle or rail car 4 Must pass UN T1 T8 Tests and be shipped as a Class 9 hazardous mat
3. Nanophosphate cells 20 C min is only a fraction of the heat rate for other Lithium Ion chemistries almost 2000 C min A123 Systems cells offer long cycle and calendar life with minimal impedance growth over the life of the cells Figure 3 3 illustrates the cells ability to retain a high percentage of their first discharge capacity over thousands of low rate cycles In addition these cells also offer extended calendar life even at elevated temperatures 3 3 Chapter 3 A123 Nanophosphate Technology inside the ALM 12V7 100 0 2 am 2 wu E 800 E 5 amp 70 0 5 8 S 600 ANAZESSOMW 1C 1C Cycling 25 C 3 6V 1005000 510 0 1000 2000 3000 4000 5000 6000 7000 8000 Cycle Number Figure 3 3 Thousands of Low Rate Cycles The ALM 12V7 3 4 Figure 3 4 ALM 12V7 Module The ALM 12V7 battery module consists of eight ANR26650 cells arranged in a four in series and two in parallel configuration 4S2P with integrated cell protection and balancing circuitry A123 Systems designed the ALM 12V7 as a drop in replacement for the 12 volt 7 Ah lead acid batteries that typically serve as a standby power source in many high availability and Chapter 3 A123 Nanophosphate Technology inside the ALM 12V7 service critical applications To ensure a seamless replacement process the ALM 12V7 features identical dimensions to 12V7 lead acid batteries uses the same 0 250 faston terminal tabs and works with
4. material initially developed at MIT A123 s low impedance Nanophosphate electrode technology provides significant competitive advantages over alternative high power technologies A123 s cell and electrode designs are optimized for low cost watt and cost watt hour performance They maintain a higher voltage than other long life systems enabling lower pack cost This long life leads to reduced lifestyle and system costs resulting in greater overall value e Nanophosphate is a positive electrode material of remarkable rate capability which is critical to high power systems Our high power products are able to pulse at discharge rates as high as 100C and deliver unmatched power by weight or volume With their low impedance and thermally conductive design you can continuously discharge A123 s cells to 100 depth of discharge at 35C rate a marked improvement over other rechargeable battery alternatives e A123 s Nanophosphate technology is highly abuse tolerant while meeting the most demanding customer requirements of power energy operating temperature range cycle life and calendar life e A123 s Nanophosphate technology delivers exceptional calendar and cycle life At low rates these cells can deliver thousands and thousands of cycles at 100 Depth of Discharge a feat unmatched by 3 1 Chapter 3 A123 Nanophosphate Technology inside the ALM 12V7 Safety 3 2 commercial Lithium Ion cells Even when cycled at 10C discharge rates th
5. the same chargers In addition the ALM 12V7 leverages Nanophosphate technology for the following key advantages over lead acid alternatives e Longer life in applications requiring repeated discharge and recharge cycles e Higher power capability both during discharge and subsequent recharge e More energy during applications requiring four hours of runtime or less e Greater degree of safety due to the fact that the batteries are continually monitored by an integral microprocessor e Easier configuration of multiple modules no external Battery Management System BMS required The advantages of Nanophosphate technology result in a powerful safe battery pack that operates with a high rate of reliability throughout a longer useful life reducing the overall cost of ownership over the battery pack s life Functional Differences with Lead Acid 12V7 Batteries The integrated cell protection and balancing circuitry responsible for the durability and additional safety features of the ALM 12V7 module also cause functional behavior that differs from typical lead acid batteries The two biggest differences are e No voltage at the terminals does not necessarily indicate a bad battery With a lead acid battery finding no voltage at the terminals often indicates the battery has reached the end of its life With the ALM 12V7 module no voltage at the terminals typically means the cell protection circuitry has interrupted current to prote
6. this document on page 1 1 e How this document is organized on page 1 2 A123 s ALM 12V7 Lithium Ion battery module UL model number Series 51 000001 is designed as a drop in replacement for the 12 volt 7 Ah lead acid batteries that typically serve as a standby power source in many high availability and service critical applications The Series PSLO00001 is recognized as a standalone battery only To ensure a seamless replacement process the ALM 12V7 features identical dimensions to 12V7 lead acid batteries uses the same 0 250 faston terminal tabs and works with typical lead acid chargers The ALM 12V7 battery pack consists of eight ANR26650 cells in a 4S2P configuration with integrated cell protection and balancing circuitry The ALM 12V7 includes a user replaceable 30 A fuse as well as a non replaceable 120 A fuse Furthermore an integrated microprocessor protects the battery pack from over voltage under voltage and over temperature conditions Purpose of this document This manual provides detailed specifications for the ALM 12V7 as well as guidance on the safe and effective operation and configuration of multiple ALM 12V7 modules for use as building blocks in various applications This manual provides information to safely connect multiple modules up to a maximum configuration of four modules in series and 10 modules in parallel 4S10P as well as how to charge and discharge the batteries 1 1 Chapter 1 About this Docu
7. 0 A as shown in Equation 4 Eq 4 Number of modules in parallel x 30 A Max Discharge Current String Discharge temperature limits For optimum life do not discharge a battery system faster than the maximum continuous discharge current or allow the batteries to self heat beyond 110 C Operation above 110 C results in accelerated performance degradation during the battery s service life At low temperatures the maximum available discharge current decreases due to increased internal impedance at lower temperatures Refer to Discharge Performance on page 3 7 for more details Chapter 5 Configuration and Operation Discharge Cut Off Voltage Limits Integrated When configuring your application stop discharges when the battery system reaches the recommended discharge cut off voltage or any module reaches 110 C To determine the recommended discharge cut off voltage for a battery system multiply the number of modules connected in series by the recommended discharge cut off voltage for a single module 8 V as shown in Equation 5 Eq 5 Number of modules in series x 8 V Cutoff Voltage battery system You can discharge the battery system at greater than the maximum continuous discharge current in short pulses as long as individual modules do not exceed 110 C The maximum pulse discharge current for each parallel string is 54 A for less than 200 ms During pulse discharges the battery system voltage can safely fall be
8. 406017 001 Rev 06 April 24 2012 A123 Systems ALM 12V7 User s Guide End User Documentation D 23 Copyright 2012 A123 Systems angie reserved SYSTEMS A123 ALM 12V7 User s Guide Copyright 2012 A123 Systems Inc All rights reserved DOCUMENT NOTICE The information contained in this manual is the property of A123 Systems Inc A123 Systems and is subject to change without notice A123 Systems reserves the right to make changes in the design of its products or components as progress in engineering and manufacturing may warrant It is the customer s responsibility to satisfy itself as to whether the information contained herein is adequate and sufficient for a user s particular use It is the further responsibility of each user to ensure that all applications of A123 Systems products are appropriate and safe based on conditions anticipated or encountered during use This document does not create any additional obligation for A123 Systems and does not constitute additional warranties and representations The A123 Systems logo is a trademark and a service mark of A123 Systems Inc Questions Please call A123 Systems Customer Service at 855 A123 ESG 855 212 3374 Revision Control This section describes the changes made to each revision of this document Revision Rev 06 Change In Chapter 5 corrected mislabeled diagram and discharge current value Rev 05 Updated images depicting series
9. Charge Current at 10A The maximum operating temperature decreases by a factor of 1 1 C per 1 000 ft of elevation above 7 500 ft Mechanical Dimensions Figure 3 5 details the mechanical dimensions of the ALM 12V7 module Chapter 3 A123 Nanophosphate Technology inside the ALM 12V7 164 5 2X 15 Figure 3 5 ALM 12V7 Mechanical Dimensions The ALM 12V7 consists of the following components 1 12V7 2 Fuse plug 3 30 A 58 V ATO style blade fuse Discharge Performance As shown in the typical room temperature discharge curve in Figure 3 6 the ALM 12V7 s voltage remains virtually flat during the discharges and the capacity doesn t change significantly no matter how fast the discharge is 3 7 Chapter 3 A123 Nanophosphate Technology inside the ALM 12V7 Terminal Voltage V i4 13 5 13 4 12 5 12 11 5 11 10 5 10 Typical ALM12V7 Constant Current Discharge Curve at Room Temperature m 1 2C 2 3A 1C 4 64 mm 2 9 24 4 18 44 T T T T T T 0 0 5 1 1 5 2 2 5 3 3 5 4 4 5 5 Discharge Capacity Ah 3 8 Figure 3 6 Room Temperature Discharge Cell resistance changes with cell temperature The warmer the ambient and or cell temperature the lower the resistance Conversely lower temperatures negatively impact the cell s ability to hold voltage under a load Figure 3 7 and Figure 3 8 illu
10. Safety Regulations on page 2 1 e Transporting Lithium lon Batteries on page 2 2 e Environmental Regulations on page 2 5 Safety Regulations e UL subject 1973 Batteries for use in Light Electric Rail LER Applications and Stationary Applications e CE EU consumer safety health and environmental regulations Signifies conformity with EMC directive 2004 108 EC e FCC Part 15 Subpart B Class A standards regulating unintentional emissions of radio frequencies from a digital device e UN 38 3 requirements for safe transportation of Lithium Ion batteries 2 1 Chapter 2 Regulations Transporting Lithium Ion Batteries 2 2 This section discusses the regulations governing the transportation of Lithium Ion cells and batteries both within the United States and internationally You should read and understand all relevant regulations discussed in this section before shipping ALM 12V7 modules This section includes the following sections e Overview on page 2 2 e Regulations by Cell Battery Size on page 2 3 e Following UN and DOT Regulations on page 2 4 The regulations discussed in this manual apply to Lithium Ion cells and batteries Once the ALM 12V7 is integrated into a host product the host product may be subject to additional transportation regulations that require additional certification testing Since A123 Systems can t anticipate every possible configuration and application of the ALM 12V7 you must verify th
11. Strings The modules can be combined together in series strings to achieve higher operating voltages by connecting the positive terminal of one module to the negative terminal of the next module The maximum number of ALM 12V7s you can connect in a series is four Figure 5 2 illustrates two ALM 12V7s connected in series for a 2S1P configuration Series 2S Parallel 1P Positive Terminal Negative Terminal 2 x 13 2 V 26 4 V nominal for 24 V Figure 5 2 Connecting Modules in Series 2S1P Configuration 5 3 Chapter 5 Configuration and Operation 5 4 e Two modules in series 2 x 13 2 V 26 4 V nominal for 24 V applications e Three modules in series 3 x 13 2 V 39 6 V nominal for 36 V applications e Four modules in series 4 x 13 2 V 52 8 V nominal for 48 V applications Parallel Strings You can combine modules together in parallel strings to achieve higher operating power and or energy by connecting like polarity terminals of adjacent modules To combine modules in parallel strings connect all like polarity wires on adjacent modules to an appropriately sized terminal block for your application Reference local electrical codes for terminal block specifications Refer to Figure 5 3 for an example of eight ALM 12V7 modules connected together in a 4S2P configuration With certain restrictions the ALM12V7 can support paralleling for added discharge current These restrictions are described below and depe
12. age by multiplying the number of modules connected in series by the recommended float charge voltage of a single module 13 8 V as shown in Equation 2 Eq 2 Number of modules in series x 13 8 V Float Charge Voltage battery system Recommended fast charge method for parallel strings Determine the fast charge current for a battery system by multiplying the number of modules connected in parallel by the maximum continuous charge current for a single module 10 A as shown in Equation 3 You can determine the maximum recommended charge voltage by multiplying the number of modules connected in series by the recommended charge voltage of a single module 14 4 V Charge the battery system at its maximum continuous charge current until you reach its maximum recommended charge voltage Apply a constant voltage hold at the maximum recommended charge voltage until the total charge time reaches the fast charge time Do not attempt a fast charge outside the recommended temperature range and stop if the battery exhibits signs of overheating such as the battery current disappearing during a charge Eq 3 Number of modules in parallel x 10 A Fast Charge Current battery system Discharging Battery Systems Recommended discharge method for strings Determine the maximum continuous discharge current for a battery system by multiplying the number of modules connected in parallel by the maximum continuous discharge current for a single module 3
13. and parallel configurations in chapter 5 Replaced all cell name references with the cell short name ANR26650 Rev 04 Updated ALM 12V7 photo to correct labeling information depicted Rev 03 Updated float voltage 20 13 8 V and added 13 8 V minimum recharge voltage Rev 02 Updated Design Release Rev 01 Initial Design Release THIS PAGE INTENTIONALLY LEFT BLANK Table of Contents About this Document Overview 1 1 Purpose of this document ccccccesssccesssseecesseececsseceesaeeceeseecccssseecessasescesseeecessaeeeessaeecceeseeeaeaees 1 1 How this document is organized cccccccccccccssssscecececssssseeeeecesesssseeeeeeceesessseeeeeeeeseesseeeeeeeesesaees 1 2 Regulations Safety RegulatiON TETUR TIU IL LT 2 1 Transporting Lithium lon Batteries ccccnncooccncnnccnonononcnnnonnnnnanonononnncnnnnnnnnnnnnnnconnnonnnnnnnnnnnnnnnnnnnns 2 2 Environmental Regulations ccccsccccccessssssseeeceeseseessseeeecessesseseeeceeseseeaseeeeeessecesaseeeeeesesseseeees 2 5 A123 Nanophosphate Technology inside the ALM 12V7 Nanophosphate Technology cccsscccesssscccsseeceessseccesseeccsseecesssseccessseeecssaeecesaseecessueeeeeaeeeesens 3 1 SAT OLY PLE 3 2 3 3 TOSALWIL2V 3 4 Applications Competitive Advantages
14. at your ALM 12V7 powered host product is compliant with all applicable regulations Refer to Table 2 3 on page 2 4 for a list of UN numbers to reference to find applicable regulations for your application Overview Rechargeable lithium ion including lithium ion polymer cells and batteries are considered dangerous goods The regulations that govern their transport are based on the UN Recommendations on the Transport of Dangerous Goods Model Regulations Transport of dangerous goods is regulated internationally by e International Civil Aviation Organization ICAO Technical Instructions and e International Air Transport Association IATA Dangerous Goods Regulations and e International Maritime Dangerous Goods IMDG Code In the United States transportation is regulated by Title part 49 of the Code of Federal Regulations or CFR s Title 49 CFR Sections 100 185 of the U S Hazardous Materials Regulations HMR contains the requirements for transporting cells and batteries Refer to the following sections within 49 CFR for specific information e Section 173 185 Shipping requirements for Lithium cells and batteries e Section 172 102 Special Provisions e Sections 172 101 178 Further information and specifications on packaging Chapter 2 Regulations The Office of Hazardous Materials Safety Administration PHMSA which is within the U S Department of Transportation DOT is responsible for drafting and writing the U S
15. batteries fail due to high temperatures or frequent UPS cycling e Lighter weight solution helps with physical installation of UPS e Lead free design supports environmentally friendly needs A123 has helped many customers realize the simplicity of installing the ALM 12V7 into backup power systems to replace lead acid solutions Installation possibilities include e Home cable backup system e Home security systems e Single computer backup UPS e High availability IT backup UPS e Telecom cell tower backup UPS e Power supplies for Computers on Wheels Light weight Long Life Solutions Many applications today are using batteries for supplemental power These applications typically require high energy density and cycle the batteries frequently Examples of these applications are e Electric bicycles e Marine applications such as sonar fish finders e Recreational camping applications such as large flashlights Chapter 4 Applications e Various portable devices such as lighting The applications listed above all look for characteristics which are consistent with the A123 value propositions Lightweight long cycle life and good energy density enable the A123 ALM products to provide superior performance in these applications Comparison to lead acid batteries quickly demonstrates the superior performance of A123 technology e A123 ALM batteries are less than half the weight of their lead acid equivalents e A123 batteries deliver more
16. circuitry leaving the module without critical safety features such as over voltage and over temperature protection A123 Systems ALM 12V7 can be stored in an environment with temperatures between 40 C and 60 C and between 10 and 90 relative humidity non condensing In addition you can store the ALM 12V7 at altitudes up to 25 000ft For long storage periods at 25 C charge the battery every three years For temperatures above 40 C charge the battery annually Do not store the ALM 12V7 at temperatures above 60 C Do not incinerate or dispose of the battery Return end of life or defective batteries to your nearest recycling center as per the appropriate local regulations 3 11 Chapter 3 A123 Nanophosphate Technology inside the ALM 12V7 3 12 Chapter 4 Applications This chapter discusses competitive advantages and potential applications ofthe ALM 12V7 battery module in the following sections Competitive Advantages on page 4 1 Applications on page 4 2 Competitive Advantages Power Safety Life A123 s ALM 12V7 is a battery module offering tremendous value in many applications The battery is designed to be a drop in replacement for standard lead acid 12V7 batteries and provide the following advantages e Higher power capability during discharge and subsequent recharge e Greater efficiency due to less energy lost during high rate applications and less power required to keep the module fully charge
17. ct the battery module Simply connect the module to a charger to restore voltage to the terminals e State of Charge SOC with an ALM 12V7 appears constant then drops suddenly Voltage for an ALM 12V7 remains relatively constant throughout the depth of discharge while voltage for a lead acid battery decreases at a linear rate Therefore determining an ALM 12V7 s SOC using the same methods to determine a lead acid battery s SOC creates the impression that the ALM 12V7 has a full charge then loses power abruptly A steady voltage across the depth of discharge is normal behavior for the ALM 12V7 Refer to Discharge Performance on page 3 7 for more details 3 5 Chapter 3 A123 Nanophosphate Technology inside the ALM 12V7 3 6 ALM 12V7 Specifications Table 3 1 ALM 12V7 Specifications Specification Maximum Discharge Current 30A Maximum Pulse Discharge Current 54 A for lt 200 ms At 25 C Ambient Operating Temperature Range 20 C to 58 C Maximum Operating Altitude 10 000 ft Operating Relative Humidity non condensing 20 to 80 Nominal Operational Voltage 25 C 13 2 V Minimum Voltage 2 V any cell Maximum Voltage 4 0 V any cell Nominal Capacity 4 6 Ah Standard Charge Voltage 14 4 V Minimum Charge Voltage 13 8 V Maximum Charge Voltage 14 4 V 15 0 V Float Charge Voltage 13 8 V Standard Charge Current at 25 C 3A Maximum Continuous
18. d e Smaller and lighter systems due to higher power and energy density e High degree of safety due to inherently stable cell chemistry and integrated protection circuitry e Limited environmental impact lead free and no hazardous material content e Longer useful life due to higher usable energy e Longer lifetime in float applications e Longer cycle life e Longer shelf storage life due to lower self discharge 4 1 Chapter 4 Applications Applications 4 2 Applications that could benefit from these competitive advantages range from sophisticated computer backup equipment and security systems to children s toys The ALM 12V7 is particularly well suited for applications in the following categories e Backup Power e Light weight Long Life Solutions While the ALM 12V7 features a sturdy case it is not designed for outdoor use or other environmentally challenging applications Backup Power The occurrence of power outages brownouts and surges are well known in business and residential environments These power events can potentially cause havoc in any environment Computer data loss and equipment damage are commonly avoided by installing Uninterruptible Power Supplies UPS that rely on lead acid batteries for power Replacing the standard lead acid batteries with A123 s ALM 12V7s helps users immediately benefit from A123 s technology e Longer useful life helps avoid costly battery replacements where lead acid
19. d FCC RF Emissions governing body in the United States UL Underwriter Laboratories Tests and Certifies safe and compliant product operation in North America vSOC Voltage based SOC algorithm A 2 THIS PAGE INTENTIONALLY LEFT BLANK THIS PAGE INTENTIONALLY LEFT BLANK
20. d by the 26650 cells inside it as well as ambient temperature and charge discharge rates Under optimal conditions the cells can deliver thousands of cycles at 100 Depth of Discharge DOD Even at 10C discharge rates the cells can deliver in excess of 1 000 full DOD cycles Refer to Cycle Life on page 3 10 for more details on cycle life Chapter 3 A123 Nanophosphate Technology inside the ALM 12V7 Terminal Specifications Safety CAUTION Storage Disposal The ALM 12V7 module utilizes the same 0 250 by 0 032 Faston terminals found on 12V7 lead acid batteries and is compatible with any appropriately sized receptacle A123 s Nanophosphate cells are more abuse tolerant than other Lithium Ion cells however correct handling of the ALM 12V7 module is still important to ensure safe operation Failure to follow the following safety instructions may result in personal injuries or damage to the equipment e Do not expose the ALM 12V7 to heat in excess of 58 C during operation 60 C in storage do not incinerate or expose to open flames e Do not short circuit the ALM 12V7 This blows the 30 A user replaceable fuse e Do not charge or discharge the ALM 12V7 outside of its stated operating temperature range Reduce charging limits for lower operating temperatures e Do not connect more than four modules in series Connecting more than four modules in series exceeds the voltage limit of the integrated protection
21. e and or capacity Configuration Options 5 2 CAUTION CAUTION You can arrange A123 s ALM 12V7 battery modules in series and or in parallel to achieve higher operating voltages and capacities for your intended application with a maximum configuration of 4S10P An external BMS or other electronics are not required to configure multiple ALM 12V7s Do not connect more than four ALM 12V7 modules in series as the total voltage exceeds the limits of the integrated protection circuitry Compromising the integrated protection circuitry increases the risk of an over voltage or over temperature event that may damage the ALM 12V7 and the host equipment Do not short circuit the ALM 12V7 This blows the 30 A user replaceable fuse Connect the ALM 12V7 modules using 8 AWG wire and any receptacle that fits a 0 250 by 0 032 Faston terminal tab The 8 AWG wire is necessary to carry the maximum current allowed by the user replaceable 30 A fuse in each module Refer to Figure 5 1 for an illustration of the components used to connect multiple ALM 12V7s Chapter 5 Configuration and Operation gt ai L 8 AWG Wire 0 250 Faston Receptacle Figure 5 1 Components Used to Connect Multiple ALM 12V7s ES NOTE Do not connect ALM 12V7 modules to battery modules of other chemistries or ALM modules of different capacities For example do not connect an ALM 12V7 to a lead acid 12V7 or an ALM12V35 Series
22. e that shipping company can ship DG Refer to Table 2 3 for proper shipping names and UN numbers for Lithium ion batteries Table 2 3 Proper Shipping Names and UN numbers contained in equipment Proper Shipping Name UN Number Lithium ion batteries UN 3480 Lithium ion batteries UN 3481 packed with equipment Lithium ion batteries UN 3481 Chapter 2 Regulations Environmental Regulations The battery pack is compliant with the following environmental regulations EU Directive 2002 95 EC for Restriction of Hazardous Substances ROHS EU Directive 2006 66 EC on batteries and accumulators and waste batteries and accumulators EU Directive 1907 2006 on the Registration Evaluation Authorization and Restriction of Chemicals REACH Management Methods for Controlling Pollution Caused by Electronic Information Products Regulation China RoHS 2 5 THIS PAGE INTENTIONALLY LEFT BLANK Chapter 3 A123 Nanophosphate Technology inside the ALM 12V7 The ALM 12V7 consists of eight ANR26650 cells using patented Nanophosphate technology and is intended as a replacement in the high end market for the common lead acid battery This chapter details the advantages of the technology behind the ALM 12V7 in the following sections e Nanophosphate Technology on page 3 1 e Safety on page 3 2 e Lifeon page 3 3 e The ALM 12V7 on page 3 4 Nanophosphate Technology Based on new highly active nanoscale
23. energy than lead acid equivalent at high rate discharges short run time e A123 batteries deliver up to ten times more cycles than their lead acid equivalents 4 3 THIS PAGE INTENTIONALLY LEFT BLANK Chapter 5 Configuration and Operation This chapter discusses configuring charging and discharging the ALM 12V7 in the following sections e Terminology on page 5 1 e Configuration Options on page 5 2 e Charging Multiple Modules on page 5 7 e Discharging Battery Systems on page 5 10 e Integrated Module Protection on page 5 11 NOTE The series PSL000001 is UL Recognized as a standalone battery only and has not been evaluated for series and or parallel configuration Terminology This chapter discusses configuring and operating ALM 12V7 modules using the following terminology Table 5 1 Configuration Terminology Terminology Definition Cell Refers to an individual ANR26650 cell that is the basis for the ALM 12V7 battery module Each ALM 12V7 contains eight ANR26650 cells combined in a 4S2P configuration Module or Battery The ALM 12V7 battery module Module Series String A string of cells arranged in series to achieve higher voltage Parallel String A string of cells arranged in parallel to achieve higher capacity 5 1 Chapter 5 Configuration and Operation Terminology Definition Battery System Battery modules connected in series and or in parallel to achieve higher voltag
24. erial 5 Packages containing more than 12 batteries or 24 cells must meet certain packaging marking and shipping paper requirements 6 Requires Class 9 markings label specification packaging and shipping papers unless transported by motor vehicle or rail car 2 3 Chapter 2 Regulations 7 Cells and batteries must pass UN T1 T8 Tests Cells and batteries that pass UN Tests are excepted from regulation NOTE The IMDG Code contains a grandfather clause for testing small cells and batteries until December 31 2013 8 Requires Class 9 markings label specification packaging and shipping papers Following UN and DOT Regulations Failure to comply with UN and DOT regulations while transporting Class 9 Hazardous Materials Dangerous Goods may result in substantial civil and criminal penalties Table 2 2 outlines a process that you can follow to help ensure that cells and batteries are shipped per the required regulations Table 2 2 Suggested Steps for Regulatory Compliance Step Number Process step Comments Insure use of UN certified packaging if applicable All dangerous goods must be shipped in UN certified packaging Packaging of cell or Battery Pack per regulations Package labeling Insure that packaging container has all required labeling Fill out proper shipping documentation Shipper s declaration for dangerous goods airway bill etc Ship package Ensur
25. ese cells deliver in excess of 1 000 full depth of discharge cycles A123 s Nanophosphate cells are more abuse tolerant than competing cells of different Lithium Ion chemistries For an illustration of the inherent safety of A123 s Nanophosphate cells using thermal ramp testing by an independent lab refer to Figure 3 1 and Figure 3 2 Runaway Flame 18650 Li AAA 3 n d TINA tras Prat TA 1200 3 200 Mixed Cathode A ERN seco NT SUMA zu TA 0 100 200 300 400 500 Temp C Figure 3 1 Heating Rate Profile Compared to Common Cathode Compositions in Competing Cells Chapter 3 A123 Nanophosphate Technology inside the ALM 12V7 Cell Ruanway 240 C 250 C fp A123 Baseline Cells Baseline Cell vent no flame N N e a 1 Baseline Cell with vent flame Vent Flame gt a Delta T Rate C min e L 183 C Vent 165 C 5l No Flame 5 100 120 140 160 180 200 220 240 260 Temperature C Figure 4 Heating rate profiles for two A123 baseline cells one cell with burning vent gases Figure 3 2 Heating Rate Profiles for two A123 Baseline Cells Figure 3 1 shows A123 s cells have a higher onset temperature for thermal runaway than other Lithium Ion chemistries Figure 3 2 shows a closer view of the data for A123 s cells illustrating how the maximum heat rate for the
26. for the next discharge Chapter 5 Configuration and Operation If operation below 23 C is required you should adhere to a current ramp rate of no more than 10 A per second to prevent sudden dips in pack voltage that could lead to inadvertent activation of the UVP mechanism Paralleling for higher charge currents Paralleling for higher charge currents is not supported at this time Series 4S Parallel 2P 9 2 Ah nominal Positive Terminal Negative Terminal 2 x 13 2 V 26 4 V nominal for 24 V Figure 5 3 Example of a 4S2P Configuration e Two series strings in parallel 2 x 4 6 Ah 9 2 Ah nominal e Three series strings in parallel 3 x 4 6 Ah 13 8 Ah nominal e Four series strings in parallel 4 x 4 6 Ah 18 4 Ah nominal 5 5 Chapter 5 Configuration and Operation Large Configuration Example Figure 5 4 illustrates a larger configuration of ALM 12V7 modules arranged in series and parallel This configuration features four series strings and four parallel strings 454 Series 45 Parallel 4P Positive Terminal Negative Terminal 4 x 13 2 V 52 8 V nominal for 48 V Figure 5 4 Example of a 4S4P Configuration 5 6 Chapter 5 Configuration and Operation Charging Multiple Modules CAUTION This section describes how to charge and discharge ALM 12V7 modules configured in series or parallel up to a maximum configuration of 4S10P Failure to follow the followin
27. g safety instructions may result in personal injuries or damage to the equipment e Do not connect more than four modules in series Connecting more than four modules in series exceeds the voltage limit of the integrated protection circuitry leaving the module without critical safety features such as over voltage and over temperature protection e Do not short circuit the ALM 12V7 This blows the 30 A user replaceable fuse Charging Modules or Battery Systems The ALM 12V7 is compatible with any 12V7 lead acid battery charger of 10 A or less Chargers that automatically detect voltage at the terminals and charge accordingly may fail to wake the ALM 12V7 from a state of under voltage protection Constant Voltage CV chargers may result in an inrush of current due to the low impedance of the cells interrupting the charge Reset the charger and continue charging normally if the charger trips The Total charge current for the group should be 10 Determine the end of charge voltage for the battery system by multiplying the number of modules connected in series by the maximum recommended charge voltage of a single module 14 4 V as shown in Equation 1 Eq 1 Number of modules in series x Recommended Maximum Charge Voltage module Charge Voltage String To prevent damage to ALM12V7 modules connected in series from a current inrush during charging ensure that the difference between battery system voltage and charger voltage is never
28. greater than 10 0 V and limit the peak inrush current to 10 A Limit the peak inrush current by minimizing charger capacitance and or providing current limiting circuitry between the charger and battery system To charge a single ALM12V7 module the maximum charge voltage is 14 4 V and the maximum charge and inrush current is 10 A Refer to the following table for recommended charge currents and voltage 5 7 Chapter 5 Configuration and Operation 5 8 Table 5 2 Examples for Charging Example Description Example 1 If the module string has 10 modules in parallel 10P and the recommended charge current per module is 10 A then the charge current for this parallel string is 10 A Example 2 If the module string has four modules in series 4S and the recommended charge voltage per module is 14 4 V then the end of charge voltage for this series string is 57 6 V 4 modules series x 14 4 V 57 6 V Example 3 If the module string has four modules in series and 10 module strings in parallel 4S 10P the recommended charge voltage per module is 14 4 V and the recommended charge current per module is 10 A then the charge current and charge voltage for the string is 100 A and 57 6 V 4 modules series x 14 4 V 57 6 V 10 modules parallel 10 A Once you reach end of charge voltage apply a constant voltage hold at this voltage until the current decays to almost zero This charges the cells t
29. iod or heavy use enabling under voltage protection e The module overheated causing the microprocessor to enable over temperature protection Solution To resolve situations where terminal voltage is absent or low 1 Allow the battery to cool and then recheck terminal voltage 2 Inspect the fuse and replace it if necessary Use only fuses that meet the specifications described in Fusingon page 5 12 Ensure the replacement fuse s voltage rating is appropriate for your application 3 Connect the battery to a charger to wake the battery and recover terminal voltage Depending on the module s voltage and state of balance it may take up to 48 hours to completely charge and balance the module 6 2 Chapter 6 Troubleshooting Multimiter shows terminal voltage low Allow battery pack to cool and recheck voltage Terminal voltage present 30 A fuse Yes blown Replace the fuse Terminal voltage Charge the battery No present Terminal voltage present Yes Begin the RMA process Yes Figure 6 1 Terminal Voltage Low or Absent Troubleshooting Flow Chart Battery Rapidly Depletes Energy between Charges Problem The ALM 12V7 rapidly depletes its energy between charging Possible causes for this problem are e The battery pack is out of balance e The battery pack has reached the end of its useful service life 6 3 Chapter 6 Troubleshooting Solution To resolve situatio
30. low the recommended discharge cut off voltage Although you can safely discharge the battery system below the recommended discharge cut off voltage do not leave the modules below this level Recharge the battery system to prevent permanent capacity loss and damage to the modules Module Protection The ALM 12V7 includes integrated protection circuitry to prevent the battery module from exceeding its voltage limits The module s circuitry interrupts either charging or discharging current if the battery is in danger of exceeding upper or lower voltage or temperature limits Over Voltage and Under Voltage The ALM 12V7 s circuitry continuously monitors cell voltage and can interrupt either charge or discharge current in the event that a cell s voltage exceeds safe operating limits The protection circuitry interrupts current if the voltage on any single cell rises above 4 0 V or falls below 2 V e If the voltage on a single cell falls below 2 V the protection circuitry enables under voltage protection preventing continued discharge until you charge the battery To avoid degradation you must recharge the battery module within 7 days The protection circuitry disables under voltage protection once you charge the module to the point where all cells are above 3 0 V e If the voltage on a single cell rises above 4 0 V the protection circuitry enables over voltage protection preventing continued charging until the voltage falls The protec
31. ment How this document is organized 1 2 This document is divided into the following parts Regulations Discusses the safety EMC environmental and transportation regulations applicable to the ALM 12V7 battery module A123 Nanophosphate Technology inside the ALM 12V7 Discusses the Lithium Ion technology inside the ALM 12V7 and its advantages compared to traditional lead acid batteries Applications Discusses various applications for the ALM 12V7 Configuration and Operation Discusses how to safely connect multiple ALM 12V7s up to a maximum configuration of four modules in series and 10 in parallel This chapter also provides details for charging and discharging multiple ALM 12V7s Troubleshooting Discusses behavior unique to the ALM 12V7 compared to traditional lead acid batteries and how to operate the battery in those circumstances Glossary Glossary of terms Chapter 2 Regulations The chapter discusses the safety EMC environmental and transportation regulations applicable to the ALM 12V7 battery module The transportation material presented here is not all inclusive of the regulations required to ship a product but is meant to inform you of the complexity involved in doing so Anyone involved in the integration of Lithium Ion battery packs into a host product must review the regulations cited here to meet compliance standards with industry regulations This chapter includes the following sections e
32. nd upon accurate balancing which typically requires fairly lengthy charge periods to ensure If impedance capacity or self discharge rates between cells vary significantly then FET failure may occur regardless of how well you adhere to these instructions This is because the overvoltage and undervoltage protection mechanisms operate based upon individual cell voltages and unfortunately you can only monitor and respond to terminal voltages Therefore these provisions for paralleling for added current assume that all cells the same way Otherwise the FETs may open unexpectedly which could lead to the failure modes previously described Paralleling for higher discharge currents 1 Before wiring multiple ALM batteries together all batteries must be individually charged to 100 SOC using a 10 A current limit To ensure that 100 SOC is reached a 14 4 V charge voltage should be maintained for at least 4 hours 2 Connect batteries together in a configuration not to exceed 4s10p 4 in series 10 in parallel 3 The entire group of batteries should then be float charged at a 10 A current according to the number of series elements 14 4 V for 1 s 28 8 V for 2 s 43 2 V for 3 s or 57 6 V for 4 s This float should be held for at least 24 hours to allow the batteries in the system to fully balance 4 To recharge the group repeat the process starting at step 3 This will ensure that all cells are once again properly balanced in preparation
33. nnections as a safety feature in the event the user replaceable fuse does not meet the above specifications and fails to protect the battery pack Blowing the secondary fuse permanently disables the ALM 12V7 as it is not user replaceable 5 15 Chapter 5 Configuration and Operation Chapter 6 Troubleshooting Chapter 6 Troubleshooting The ALM 12V7 is an extremely reliable battery module that provides greater useful life than comparable 12V7 lead acid batteries Despite the high reliability of the ALM 12V7 you may encounter situations where the battery module does not operate as expected These situations are typically the result of misuse abuse or a non optimal operating or storage environment This chapter details potential issues you may encounter with the ALM 12V7 and the appropriate troubleshooting procedures Charger Trips using Constant Voltage Problem CV charger trips when charging the ALM 12V7 This is due to the low impedance of the module creating a current inrush Solution Reset the charger and try again Terminal Voltage Absent or Low Problem Using a multimeter to check terminal voltage shows the terminal voltage is low Possible causes for this problem are e Blown fuse e The voltage of a cell within the module dropped below 2 V causing the microprocessor to enable under voltage protection 6 1 Chapter 6 Troubleshooting e The module s SOC dropped below 5 from either an extended idle per
34. ns where the battery rapidly depletes its energy between charges 1 Apply a float charge 13 8 V 10 A for 48 hours to balance the battery pack s cells 2 Replace the battery pack Battery Current Disappears when Charging Problem Battery current disappears when charging Possible causes for this problem are e The battery overheated enabling over temperature protection e The battery pack is out of balance e Charger voltage is too high Solution To resolve situations where current disappears when charging 1 Allow the battery to cool 2 Apply a float charge 13 8 V 10 A for 48 hours to balance the battery pack s cells For more details on charging battery modules or strings refer to Charging Modules or Battery Systems On page 5 7 3 Reduce charger voltage to 14 4 V or less 30 A Fuse Blows Frequently Problem The user replaceable 30 A fuse blows frequently Possible causes for this problem are e The fuse was replaced with a fuse that does not meet the specifications detailed in User Replaceable Fuse on page 5 12 e Failure to ensure correct polarity when connecting the battery pack to other battery packs or a host product s output terminals 6 4 Chapter 6 Troubleshooting e The battery exceeded maximum current specifications while charging or discharging the battery Solution To resolve situations where the battery s 30 A fuse blows frequently 1 Ensure you are using a fuse that mee
35. o 100 state of charge SOC Refer to Figure 5 5 for an illustration Charger holds output to a steady float voltage E 3 Charger holds 1 el steady constant e current output i 5 5 Battery Battery Charge current tapers Current down to almost zero time Figure 5 5 Battery Voltage and Current During Recharge Relationship Between Charge Limits and Temperature Due to the chemistry of Lithium Ion cells the cells cannot accept as much charge current at lower temperatures without risking permanent loss of capacity As the cells temperature rises during the charging process they can gradually accept higher currents To maintain optimum performance and durability of the ALM 12V7 A123 Systems recommends the following charge limits based on ambient temperature Chapter 5 Configuration and Operation Table 5 3 Charge Rate by Temperature Temperature C Charge rate 20 C 5 0 9 A 10 C 2 2 3 A 0 1C 4 6 A 10 2C 9 2 A 20 4C 10 A 1 Maximum recommended continuous charge rate is 10A 5 9 Chapter 5 Configuration and Operation Recommended float charge method for an ALM 12V7 battery system If you hold the voltage of the battery system at the end of charge voltage after reaching 100 SOC for prolonged periods of time lower the end of charge voltage to the recommended float charge voltage Determine the recommended float volt
36. only be found in automotive parts retailers as well as electronics retailers Ensure the replacement fuse s voltage rating is appropriate for your application To replace the 30 A 58 V fuse 5 12 1 Hold the fuse plug at the lower lip indicated in Figure 5 6 then remove it and place it in a safe location Do not lose it Chapter 5 Configuration and Operation Figure 5 6 Removing the Fuse Plug Remove the 30 A fuse using an ATO fuse puller commonly available in hardware or automotive supply stores Replace the fuse with a 30 A 58 V ATO style blade fuse manufactured by LittleFuse PN 142 6185 5302 a Place the top of the replacement fuse in the fuse plug Covering the fuse with the fuse plug prior to inserting the fuse into the battery pack is the easiest way to ensure proper fitment of the fuse plug Figure 5 7 Fuse Fitment in the Fuse Plug Chapter 5 Configuration and Operation b Insert the replacement fuse and fuse plug into the battery pack Figure 5 8 Inserting the Fuse and Fuse Plug into the ALM 12V7 c Ensure that the fuse plug is flush with the module as shown in Figure 5 9 Figure 5 9 Fuse Plug Flush with the ALM 12V7 Module 4 Connect the module to a charger to wake the battery 5 14 Chapter 5 Configuration and Operation Secondary fuse In addition to the user replaceable 30 A fuse A123 Systems integrated a secondary 120 A fuse into the battery pack s cell co
37. sides in Battery Management System The Battery BMS Management System refers to the collection of electronics responsible for monitoring and controlling the ESS C Rate An electrical current corresponding to that which will fill or empty a cell in one hour Appendix A Glossary Term Acronym Meaning Constant Current A method to charge or discharge a cc battery in which the current is held constant independent of the battery s terminal voltage CE Consultants Europe Tests and Certifies safe and compliant product operation in Europe A single encased electrochemical unit one positive and Cell one negative electrode which exhibits a voltage differential across two terminals Current Interrupt Device A small device integrated CID into a cell designed to interrupt the flow of current through its terminal when too much pressure or current exists in the cell Constant Voltage A method to charge a battery in cv which the terminal voltage is held constant and the current is determined by the power path impedance or some active current limiting DVT Design Verification Testing ESS Energy Storage System iSOC Current based SOC algorithm OCV Open Circuit Voltage voltage reading of a battery when there is no current going in or out of it Original Equipment Manufacturer in reference to this OEM document the maker of the equipment into which an ESS is installed and use
38. strate the impact ambient temperature has on the ALM 12V7 s ability to hold voltage Chapter 3 A123 Nanophosphate Technology inside the ALM 12V7 Typical ALM12V7 Constant Current Discharge Curve at 0 C 14 1 2C 2 34 13 5 e 1 4 6A mw 2C 9 2A 13 4 AC 18 44 125 2 v 77 5 E 12 E 11 5 11 10 5 10 T T T T T T T T 1 0 5 1 5 2 2 5 3 3 5 4 4 5 5 Discharge Capacity Ah Figure 3 7 Discharge Curve at 0 C 3 9 Chapter 3 A123 Nanophosphate Technology inside the ALM 12V7 Terminal Voltage V 14 13 5 12 5 17 11 5 11 10 5 10 S Typical ALM12V7 Constant Current Discharge Curve at 45 C 1 2C 2 3A 1C 4 64 2C 9 24 a 4C 18 44 0 0 5 1 15 2 2 5 3 3 5 45 5 Figure 3 8 Discharge Curve at 45 C helf Life All ALM 12V7 battery packs ship from the factory at 50 SOC and can retain at least 10 SOC after 1 year of storage at temperatures not exceeding 25 C Note that higher storage temperatures reduce impedance and accelerate the rate of self discharge Following this 1 year period the SOC falls below 10 and the terminals become disconnected open The ALM 12V7 can remain in this state for a minimum of 2 more years To reactivate the terminals the battery must be recharged Cycle Life The ALM 12V7 s cycle life is determine
39. tion circuitry disables over voltage protection once the voltage falls below 3 6 V 5 11 Chapter 5 Configuration and Operation Under voltage protection creates an open circuit removing voltage from the terminals With a lead acid battery finding no voltage at the terminals often indicates the battery has reached the end of its life With the ALM 12V7 module no voltage at the terminals typically means the cell protection circuitry has interrupted current to protect the battery module Simply connect the module to a charger to restore voltage to the terminals Over Temperature The ALM 12V7 s circuitry continuously monitors the battery pack s temperature and can interrupt current if the module exceeds 110 C Module temperature must fall below 70 C before the protection circuitry restores current Balancing Fusing Over time the cells inside a batter pack diverge in both capacity and SOC An advantage of the ALM 12V7 is the circuitry continuously monitors the capacity and SOC of each individual cell and balances the battery module to ensure maximum capacity Completely balancing the battery module can take up to 48 hours User Replaceable Fuse A 30 A 58 V user replaceable ATO style blade fuse manufactured by LittleFuse PN 142 6185 5302 protects the ALM 12V7 from short circuits If required you must replace the fuse with a LittleFuse PN 142 6185 5302 The use of other fuses voids your warranty The fuse can comm
40. ts the fuse specifications detailed in User Replaceable Fuse on page 5 12 2 Verify correct polarity on all connections 3 Do not exceed maximum current specifications while charging or discharging the battery Voltage Drops Abruptly Problem Battery voltage appears constant then drops abruptly Solution This is normal for A123 s cells Constant voltage throughout the battery s SOC ensures maximum usable life Once the voltage of a cell within the module drops below 2 V the ALM 12V7 s circuitry enables under voltage protection which creates an open circuit at the terminals Refer to Nanophosphate Technology on page 3 1 for more details on the cell technology within the ALM 12V7 6 5 THIS PAGE INTENTIONALLY LEFT BLANK Appendix A Glossary Appendix A Glossary This appendix contains the following sections e Terminology Table on page 1 Terminology Table The following table describes the terminology used in this document Table A 1 Definitions and Acronyms Term Acronym Meaning ACR Alternating Current Resistance AH Amp Hour is a unit of measure of charge that can be stored or delivered to from a battery One or more cells which are electrically connected Battery together by permanent means including case terminals and markings Battery Control Module The Battery Control Module is BCM necessary to aggregate information from modules and communicate with the system the ESS re
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