FIAMM SoNick I&O - 48TL160H rev.0
– July 2013
pag.1
Page 1: ...FIAMM SoNick I O 48TL160H rev 0 July 2013 pag 1 ...
Page 2: ...TERY INSTALLATION 7 3 1 Tools and Hardware Required 7 3 2 Battery Layout and Mounting Orientation 7 3 3 Battery Front Panel 8 3 4 Power Cable Connection 9 3 4 1 Individual connection 9 3 4 2 Parallel Connection 10 3 5 Data Cable Connection 11 3 5 1 Com port pin out 11 3 5 3 Alarm Dry contact configuration 11 3 5 4 Single battery installation 12 3 5 5 Multiple batteries installation 12 3 6 Battery ...
Page 3: ...ttery Specification 16 5 3 Battery Labels 17 5 3 1 Front label 17 5 3 2 Top label 17 5 3 2 Side BMS label 18 5 4 Battery Alarms 18 5 4 1 Warnings alarms list 19 5 5 Service Life Definition 20 5 6 Extended Outages 20 5 7 Light Emitting Diodes LED s explanation 20 5 8 Display 21 5 9 Safe Technology 21 5 10 Battery Protection 21 5 10 1 Electrical Protection 21 5 10 2 Thermal Protection 22 5 10 3 Mech...
Page 4: ...e internal temperature is below the battery acts as a passive device Before use be sure to fully understand the battery functionality described in this manual 2 GENERAL INFORMATION 2 1 Introduction The 48TL160H is a 48 Volt 160Ah complete battery system designed for stationary applications This battery assembled with four strings of Sodium Nickel cells in a 20 cell series configuration is provided...
Page 5: ...tified area of the warehouse equipped with Class D fire extinguishers The battery can be stored for any length of time in the cold state without changing its characteristics or state of charge The battery has an extremely high resistance in the cold state and even a very low current can damage the battery when cold Do not try to disassemble the battery management system BMS and apply any load or p...
Page 6: ...ng this product must comply with all the rules and regulations covering the shipping of dangerous goods UN number 3292 Batteries or cells containing sodium Class 4 3 Water reactive substances In contact with water produces flammable gas Packing group Il Materials of medium danger Packing instructions 433 for air shipment P408 for road shipment IMDG for sea shipment Kemler nr not identified ERG 4W ...
Page 7: ...s Multi meter 3 2 Battery Layout and Mounting Orientation The FIAMM SoNick 48TL160H battery when active contains some materials in a liquid form Even though the battery is fully sealed the maximum permanent inclination when installed is 30 degrees During handling when the battery is cold all internal materials are in a solid state a temporary placement with angles greater than 30 are allowed In an...
Page 8: ... the front panel of the battery as indicated in the fig 5 Some connection n 2 3 4 6 7 8 of the fig 5 are protected by six plastic screw plugs All the connections of the 48TL160H battery are described in the table D The IP rating of the battery is guarantee only if all the plastic plugs in the front panel are properly screwed in If the higher IP rating is required while one or more cables are perma...
Page 9: ... two or more batteries Parallel connection is allowed Each 48TL160H battery is a 48 Vdc battery and is to be considered as a 48 Vdc battery system If there is a switch in the battery line please turn it off before connecting the power cables to the battery Otherwise please note that sparks may occur In any case the battery and the BMS are not damaged 3 4 1 Individual connection 1 Remove the termin...
Page 10: ...ection is necessary a bolt on the side of the battery can be used as indicated in the picture 8 below 7 If no data connection is being used secure all the protective dust caps provided with the battery on each data port Figure 8 3 4 2 Parallel Connection 48TL160H batteries can be connected in parallel to the same rectifier There is no limit in the number of the batteries that can be paralleled 1 B...
Page 11: ...5 CanBus 1 ALARM dry contact NC 2 ALARM dry contact C 3 ALARM dry contact NO 4 Remote ON OFF 5 Remote ON OFF 6 GND_485 GND_CAN 7 RS485 D CAN_L 8 RS485 D CAN_H Table E 3 5 2 Remote power on off Battery can be turned on and off applying or not a DC voltage 12 60V between the pins n 4 and 5 of the com port Remote battery powering is enabled only when the battery switch is the OFF position When the ba...
Page 12: ...ation of the data cable is possible Output port of one battery should be connected with the input port of the following battery as showed in the figure 11 With this configuration all the battery of the chain are connected to the same communication bus RS485 or CanBus and each single battery have to be named with the software configuration Maximum number of batteries that can be connected in the sa...
Page 13: ...e ON position The display should indicate INIT and the green led 1 Fig 12 on the front panel should start blinking indicating that the BMS is powered and the battery is not yet connected to the DC Bus the internal power switch is still open Figure 12 4 If the battery internal temperature is below 265 C 518 F the warm up phase is started see section 4 1 of this manual till the target temperature is...
Page 14: ...used In any case the BMS is fully compatible with any typical rectifier used in the market If the BMS detects that the SOC of the battery is below 100 the charge phase is automatically started This is indicated by the blue LED which will turn solid on while the display of the battery alternatively shows all the charging parameters voltages current Battery recharge time depends on the current avail...
Page 15: ...y Cool Down The 48TL160H battery is kept at its operating temperature with three internal heaters controlled by the BMS and it is insulated with special insulation material to limit both the thermal losses and the temperature gradients inside the battery If the battery is operative ON LINE the thermal management of the BMS keeps the internal temperature at a minimum of 265 C As soon as the battery...
Page 16: ...eters such as voltages currents temperatures insulation levels providing a continuous monitoring of the operating conditions Redundant Control the controller is equipped with a safety redundant microprocessor Watchdog for safe operations Battery communication the BMS has various communication capability using different communication ports USB RS485 optional CAN Bus or Ethernet 5 2 Battery Specific...
Page 17: ...hree visible labels located as in the picture 13 below Fig 13 5 3 1 Front label The label in Fig 14 contains battery technical information and the LED explanation legend Fig 14 5 3 2 Top label The label in Fig 15 contains battery technical information the production date and the battery serial number Fig 15 ...
Page 18: ...he battery Work on batteries only after instruction by qualified staff Wear eyes protection and protective clothing when working with batteries Observe accident prevention regulations 5 4 Battery Alarms Battery management system issues warnings or alarms depending on the battery working conditions or to the presence of internal faults Depending on the criticality of the situation the front Red LED...
Page 19: ...ure 18 CM E String_Current_Measure_Error HW Recoverable Alarm LONG Current measurement circuit failure 19 HWFL Hw_Failure HW Unrecoverable Alarm NULL BMS hardware failure 20 HWEM HW_Emergency HW Recoverable Alarm NULL Hardware protection system activated 21 ThM Ths_Max TEMP Recoverable Alarm LONG High heatsink temperature alarm 22 vsm1 Vstr_min_1 DISCH Recoverable Alarm SHORT Battery String voltag...
Page 20: ...D COLOUR INDICATION NOTE ACTION SOLID GREEN Battery ready to operate connected to the DC bus The battery is fully charged State of Charge SOC 100 BLINKING GREEN BLINKING BLUE Battery is warming up not connected to the DC bus Temperature is below operational Charging or discharging is not allowed SOLID GREEN SOLID BLUE Battery under charge connected to the DC bus Battery SOC is 100 Discharging is a...
Page 21: ...l insulation complex which is composed by a number of micro porous silica panels with the appropriate thickness to provide the right level of insulation minimizing the thermal losses The outer stainless steel battery box contains the inner box and the thermal insulation barrier and provides the adequate mechanical strength and a sealed construction All of the active materials are safely and perman...
Page 22: ... 350 C 662 F 5 10 3 Mechanical Protection Batteries are packed with a double stainless steel case and cells are hermetically sealed with metal cases which fully enclose the active materials and which are so constructed and closed to prevent the release of the active materials under normal conditions 5 10 4 Reliability A battery failure in a multi battery installation will not cause the battery bac...
Page 23: ... using a constant voltage DC power supply Excess of charging capacity is not a concern because internal battery circuitry automatically limits the charging current to ensure the safe and optimum operation of the battery The graph below shows the recharge time for various initial state of charges These results can be obtained when the recharge power required by the battery std setting 40A is fully ...
Page 24: ...140 F Final SOC Initial SOC 25 50 75 100 0 1 3 3 0 5 5 12 4 25 1 4 3 4 9 2 50 1 7 6 0 75 2 2 100 III Battery Floating The float power consumption of the 48TL160H battery depends on the temperature of the ambient where the battery is installed At 20 C the power consumption is around 50W ...
Page 25: ...consume more energy than at higher ambient temperatures but the capacity or energy reduction is minimal During operation at high temperatures capacity or energy are not affected Capacity Current 48TL160H Capacity Ah constant current discharge 20 60 C 4 140 F End voltage V Discharge time h 45 44 43 42 Terminated by BMS Ah Vfin 2 105 120 132 3 122 139 149 155 159 41 5 4 133 148 157 160 160 42 3 5 13...
Page 26: ... 4 33 37 39 40 40 42 3 5 28 31 32 32 32 43 4 7 21 22 22 22 22 44 3 10 15 16 16 16 16 44 9 Energy Power 3 5 4 4 5 5 5 5 6 6 5 7 7 5 8 8 5 0 500 1000 1500 2000 2500 3000 Energy KWh Power W 48TL160h Energy Vs Power at various final voltages DCH end by BMS DCH voltage limit 42 V DCH voltage limit 43 V DCH voltage limit 44 V DCH voltage limit 45 V 8 h 3 h 5 h 4 h 2 h 10 h 15 h 20 h 7 h 6 h 30 h ...
Page 27: ... 6 7 6 7 3 15 h 7 6 45 4 7 6 7 6 7 6 7 6 20 h 7 6 45 9 7 6 7 6 7 6 7 6 30 h 6 9 46 0 6 9 6 9 6 9 6 9 48TL160h Power kW 20 60 C 4 140 F End Voltage V Termination By BMS 42 43 44 45 Discharge time h kW Vfin 2 h 2 70 2 40 3 h 2 40 41 3 2 35 2 25 2 10 1 85 4 h 1 85 42 4 1 85 1 80 1 70 1 55 5 h 1 50 43 4 1 50 1 50 1 45 1 30 6 h 1 25 43 9 1 25 1 25 1 25 1 15 7 h 1 10 44 5 1 10 1 10 1 05 1 00 8 h 0 95 44...
Page 28: ...below shows the internal temperature evolution of a 48TL160H battery during the cool down process VI Battery internal resistance The graph below shows the resistance trend The measured values includes the battery electronic controller internal resistance Battery Management System ...
Page 29: ...FIAMM SoNick I O 48TL160H rev 0 July 2013 pag 29 ...
Page 30: ...FIAMM SoNick I O 48TL160H rev 0 July 2013 pag 30 ...
