Varta 56650 764 098 Technical Handbook Download

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3 Introduction of ASB

Application Specific Batteries (ASB) is

VARTA’s new range of lithium-rechargeable battery products

from VARTA Storage GmbH, offering products in the voltage range of 24V

– 48V for modern systems

and applications.

We offer a growing range of battery packs that are immediately available for high-energy or high-

power applications. All ASB battery packs are fitted with an electronic battery management system

(BMS) with protection against unsafe conditions. All cells used comply with the requirements of the

safety standard UL1642 and the packs in this handbook are certified to additional safety standard

IEC62133-2:2017 as well as UN38.3 requirements for transportation.

SYSTEM HIGHLIGHTS OF VARTA STORAGE ASB RANGE:

►

Excellent energy density

►

Zero maintenance requirements

►

Different form factors

►

Low self-discharge and wide temperature
range

►

~24V and ~48V versions

►

Up to 40kWh systems using modular
approach

►

IEC62133-2:2017 certification

►

Mechanical stacking/locking design

►

CAN Bus Communications (CANopen)

►

ISO9001 certified for design and
manufacture

►

Excellent cycle life (see PI-Sheet)

►

2 year manufacturer’s limited warranty

Comparison of different rechargeable battery systems regarding their energy densities

Summary of Contents for 56650 764 098

Page 1: ...1 ...

Page 2: ...e battery 13 6 1 Easy Blade 13 6 2 Easy Block 14 6 3 Included in the box 14 6 4 Additional systems requirements 14 6 5 Push Button 15 6 6 LED indications 15 7 Setup a system 17 7 1 Mechanical connection 17 7 2 Electrical connection 19 7 3 Configuration of a system 20 7 4 Start the battery system 21 7 5 Shut down 22 8 CAN Communication 22 9 Easy Blade Cooling concept 22 10 Charging 23 11 Error 23 1...

Page 3: ...y www varta storage de Tel 0049 9081 240 86 60 power varta storage com Version 2 Date December 2020 About this manual Please read this instruction manual carefully before beginning any kind of work It contains important information in order to ensure problem free performance of your batteries Please ensure that you have the latest version of all technical materials by downloaded from below link ht...

Page 4: ...ng disposal 1 2 General hazard sources If the following instructions for handling the device are not observed this might lead to personal injury or damage to the battery or your device for which VARTA Storage GmbH will accept no liability a Danger of electrical voltage WARNING Contact with electrical voltage Risk of fatal injury from electric shock Keep the module always sealed Pay attention to an...

Page 5: ...erial damage Do not use water for cleaning the module Never put down containers with fluids beverage containers and the like on electrical systems The relative humidity inside the room must not exceed 85 Do not clean the system with agents containing acid lye or solvents c Danger from heat ATTENTION Insufficient ventilation of the system Overheating of the system possible Keep the ventilation open...

Page 6: ... and is non permanent 2 nd Level Protection for over voltage under voltage over current short circuit over temperature under temperature It is controlled by the BMS software and is permanent 3 rd Level Protection passive with current fuse on board 1 4 Certification The battery is qualified acc to UN Recommendations on the Transportation of Dangerous Goods UN Manual of Test and Criteria Part III su...

Page 7: ...ements of the safety standard UL1642 and the packs in this handbook are certified to additional safety standard IEC62133 2 2017 as well as UN38 3 requirements for transportation SYSTEM HIGHLIGHTS OF VARTA STORAGE ASB RANGE Excellent energy density Zero maintenance requirements Different form factors Low self discharge and wide temperature range 24V and 48V versions Up to 40kWh systems using modula...

Page 8: ...the end of discharge voltage is reached Nominal Capacity The nominal capacity C denotes the capacity amount in Ah Ampère hours that the battery can deliver at the 5h discharge rate 0 2 C The reference temperature is 22 C 3 C if not otherwise stated and the final discharge voltage will also be stated Available Capacity Factors which affect the available capacity are Rate of discharge End of dischar...

Page 9: ... are first choice for a number of modern high tech products in fields such as robotics Automated Guided Vehicles AGV related Logistics and Agricultural solutions and more They provide long lasting reliable main power occupying a minimum of space and weight in the corresponding devices VARTA Storage ASB batteries fulfill the most important design in requirements Reliable high power output design fl...

Page 10: ...e V 25 9 51 8 Operating Temperature Charging 0 o C to 45 o C 0 o C to 45 o C Discharging 20 o C to 55 o C 20 o C to 55 o C Storage 1 to 3 month at 20 o C to 45 o C 1 year at 20 o C to 24 o C 1 to 3 month at 20 o C to 45 o C 1 year at 20 o C to 24 o C Life Expectance typical No of cycles on Cmin 1 200 80 1 200 80 Miscellaneous NTC Yes Yes Certification UN38 3 IEC62133 2 2017 UN38 3 IEC62133 2 2017 ...

Page 11: ... 51 2 Operating Temperature Charging 0 o C to 50 o C 0 o C to 50 o C Discharging 20 o C to 60 o C 20 o C to 60 o C Storage 1 to 3 month at 20 o C to 45 o C 1 year at 20 o C to 24 o C 1 to 3 month at 20 o C to 45 o C 1 year at 20 o C to 24 o C Life Expectance typical No of cycles on Cmin 4 000 80 10 000 60 4 000 80 10 000 60 Miscellaneous NTC Yes Yes Certification UN38 3 IEC62133 2 2017 UN38 3 IEC6...

Page 12: ...13 6 Description of the battery 6 1 Easy Blade ...

Page 13: ...for the negative terminal and an M8 screw type for the positive terminal For connection of the modules an additional bus bar or wires with cable lug are needed b Communication cable The communication cable is not provided by VARTA These are available from our distributors See contact details on page 7 VARTA recommends to use Tyco Amphenol LTW 12 05BMMA SL8001 or similar c CAN termination resistor ...

Page 14: ...arger datasheets can be provided on request for more information on charging see chapter 10 Description Material number Remark Easy Charger 24 V 57020101401 Easy Blade 24 V Easy Block 24 V Easy Charger 48 V 57021101401 Easy Blade 48 V Easy Block 48 V AC Cord 3m USA 37000727150 Available additionally AC Cord 3m EU 37000800751 Available additionally 6 5 Push Button Push the button to wake up and to ...

Page 15: ... s 0 2 0 2 0 2 0 6 g Reversible error e g over temperature over current LED s h No valid Node ID or double Node ID detected LED s 0 2 0 2 0 2 0 6 i Switch to Bootloader Mode LED s 0 1 0 1 0 1 j Bootloader is active LED s k Node ID assignment in process LED s 0 3 0 3 0 3 0 6 ...

Page 16: ...le module The modules can be connected in x1 or z2 direction for Easy Blade For Easy Block x3 and or y3 directions are possible via two module connectors shown below in black Place the module connectors inside the recess of two modules see below picture The module connectors are asymmetric and have a broad and a narrow side If the orientation of the modules is wrong e g in case of serial connectio...

Page 17: ...considered in the final design of the application For removal of the module connector loosen the screw and remove the module connector If the connector is stuck use a screwdriver for pulling it out of the recess via the side opening in the connector The modules can be connected in z1 Easy Blade and z3 Easy Block directions You can stack the batteries via the design features on the bottom and on th...

Page 18: ...p 24V and 48V battery modules within a single system The next steps describe how to connect the battery modules in parallel Step 1 Minus terminal Connect the Power Minus of all modules in parallel Tighten it with a torque of max 3 9 Nm Please note the Power minus is marked with the symbol For connection of the modules an additional bus bar or a wires with cable lug is needed Step 2 Plus terminal C...

Page 19: ...until the LEDs starts flashing orange Alternatively the ON OFF signal at the M12 connector can be connected to GND by an external switch Step 2 Press the button on any battery for at least 5s until the LED on this battery turns red 300ms off 300ms green 300ms and off 600ms until the configuration is done LED green See also chapter 6 6 k We recommend to check update the firmware of your battery her...

Page 20: ... connector permanently to ground Pin 3 Note Wake Up by the external switch is prioritized In case the battery has been turned off while the external switch was active and will be turned on again via the push button the button only needs to be pressed for 500ms Please wait at least 3 seconds before turning on the battery again after turning off to ensure internal energy has been discharged Pin out ...

Page 21: ... the ON OFF pin in the CAN connector Method 3 only applies for single modules If no charging discharging below a set threshold 5A default is detected within 3h the single module shuts down automatically This 3h value and the current threshold is a default and can be changed in the CAN device settings For multi module systems there is no auto shut down 8 CAN Communication The CAN Protocol Overview ...

Page 22: ... 15 000 mA in High Temp Range Write 15000dez in object 0x3F00 7 4 Save values permanent in EEPROM Write 7211dez in object 0x2010 1 Check the Parameters after a Reboot of the battery Read object 0x3100 2 and 0x3100 4 11 Error In case of an unexpected behavior of the battery or if any threshold limit is violated the battery will store an internal error event The LED of the battery will be steady red...

Page 23: ...RGE_OCC_1 23 ERROR_NR_I_CHARGE_OCC_2 24 ERROR_NR_I_CHARGE_OCC_3 25 ERROR_NR_I_DISCHARGE_SC 26 ERROR_NR_I_DISCHARGE_OCD_1 27 ERROR_NR_I_DISCHARGE_OCD_2 28 ERROR_NR_I_DISCHARGE_OCD_3 29 ERROR_NR_I_AKKU_DIFF_ERROR 30 ERROR_NR_SCND_SPN_MIN_ERROR 31 ERROR_NR_SCND_SPN_MAX_ERROR 32 ERROR_NR_SCND_UC_FET_ENABLE 33 ERROR_NR_SCND_CURRENT_SENSE_EIN 34 ERROR_NR_SCND_VOLTAGE_SENSE_EIN 35 ERROR_NR_SCND_TEMP_CELL...

Page 24: ... master battery 12 1 Communication within the battery system All data which is needed to operate a battery system is transferred via Process Data Objects PDOs Each battery transmits data in cyclic intervals with the following definition based on Node ID 1 PDOs sent by other Node IDs increase the CAN ID e g TPDO_1 sent by Node ID 4 has CAN ID 0x184 12 2 Communication sent by the battery master for ...

Page 25: ...e Node ID Data Event Information Status Warning Status Error Status Charge Ctrl Stat Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 all modules this module CHG FET closed all modules this module are almost empty all modules this module empty all modules this module fully charged bypass FET on all modules this module DSG FET closed Battery Information Status Register Description master slave Bit 15 14 1...

Page 26: ...when the charger is used as on board charger and stays connected at the system We want to use the Delta Q charger as a stationary charger so it will be usually disconnected from the vehicle after operation Do we need to implement another termination resistor on the vehicle to close the charger end of the CAN Bus Yes the bus needs to be terminated at both physical ends of the bus In case of short c...

Page 27: ...f the individual modules in a system Important For this reason if modules are changed within a system which have different state of charge levels we recommend first to fully charge the pack to equalize all modules This will prevent one module being used within a system to handle high currents intended for multiple modules which could cause a safety trip in the electronics Can the Module accept reg...

Page 28: ...ycle life full 4 000 cycles are achievable What is recommended for Fast Charge and what is recommended for Cycle Life Easy Blade to achieve cycle life of 1 200 cycles and beyond the max charge current recommended is 0 5C discharge current of 0 5C High charge rates will have a significant negative effect on cycle life Easy Block Max charge current allowed is 1C and it will have minimal impact on li...

Page 29: ...s CAN required that the batteries are communicating with the charger Yes this is correct Charging is only possible with CAN communication Is the communication modulated onto the direct current signal or is a separate data line required here that has to be plugged in manually Additional signals via a separate plug connection are required for communication Does Varta provide some software tool to in...

Page 30: ...atory Otherwise the battery will get stuck in SDO write errors Will the battery perform SDO interactions with the charger even after PDO communication starts No it will not 13 4 Parallel Connection Is it possible to add additional modules in parallel after the system is already configured Yes it is possible Please switch the batteries off before adding modules After adding modules start the system...

Page 31: ...max 80 average SOC to extend the expected life up to 10 years Easy Blade max 80 average SOC to extend the expected life up to 4 years What is the shelf life of the modules Easy Blade Shelf life 24 months when shipped from VARTA conservative estimate Easy Block Shelf life 24 month when shipped from VARTA conservative estimate Do you have any recommendations for the storage charging of these batteri...

Page 32: ...utdown timer can be set via object 0x3F00 4 This is only for standalone modules not multi module systems Multi module systems don t support this function Steps to follow 1 Code for write permission Write value 1815dez to object 0x2010 1 2 Timer value in seconds Write value to object 0x3F00 4 e g 604 800dez for 7 days 3 Save changed parameter permanently Write 7211dez to object 0x2010 1 We want to ...

Page 33: ...com Zuiderlaan 14 bus 10 B 1731 Zellik T 32 0 2 462 01 00 F 32 0 2 462 01 25 E belgium texim europe com Martin Kollar Strasse 9 D 81829 München T 49 0 89 436 086 0 F 49 0 89 436 086 19 E germany texim europe com St Mary s House Church Lane Carlton Le Moorland Lincoln LN5 9HS T 44 0 1522 789 555 F 44 0 845 299 22 26 E uk texim europe com Warwitzstrasse 9 A 5020 Salzburg T 43 0 662 216 026 F 43 0 66...

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