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Safety Unit for Lithium Battery Packs Manual for the Lithium Battery Safety Unit LBSU-4-100 Version: Worley Energy Cells Group Singapore Tel: +65 9792 7656 Fax: +65 6735 7444 [email protected] www.worley.com.au/wecs 1.0 1 Contents 1 CONTENTS ................................................................................................................................................. 2 2 DISCLAIMER ............................................................................................................................................. 3 3 INTRODUCTION ....................................................................................................................................... 4 4 DESCRIPTION OF THE HARDWARE .................................................................................................. 4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 STRUCTURE OF THE SAFETY UNIT ............................................................................................................. 4 POWER SUPPLY ......................................................................................................................................... 4 VOLTAGE INPUTS ...................................................................................................................................... 5 TEMPERATURE SENSORS ........................................................................................................................... 7 RESET OUTPUT .......................................................................................................................................... 7 LOAD RELAY OUTPUT ............................................................................................................................... 8 SERIAL INTERFACE (RS232) ...................................................................................................................... 8 FRONT PANEL ............................................................................................................................................ 9 5 TECHNICAL DATA................................................................................................................................. 12 6 APPENDIX A ............................................................................................................................................ 13 2 www.worley.com.au/wecs 2 Disclaimer THIS SAFETY UNIT IS A PROTOTYPE AND THEREFORE YOU MUST AGREE THE TERMS AND CONDITIONS DEFINED BELOW; BEFORE YOU USE THE SAFETY UNIT. YOU ACKNOWLEDGE AND AGREE THAT USE OF THE SAFETY UNIT IS AT YOUR OWN RISK AND THAT IT IS PROVIDED WITHOUT ANY WARRANTIES OR CONDITIONS WHATSOEVER. WORLEY DOES NOT WARRANT THAT THE FUNCTIONS OF THE SAFETY UNIT WILL MEET YOUR REQUIREMENTS OR THAT THE OPERATION OF THE SAFETY UNIT WILL BE ERROR FREE. YOU ASSUME RESPONSIBILITY FOR SELECTING THE SAFETY UNIT TO ACHIEVE YOUR INTENDED RESULTS, AND FOR THE RESULTS OBTAINED FROM THE SAFETY UNIT. YOU ACKNOWLEDGE THAT THE SAFETY UNIT IS NOT INTENDED FOR USE IN (I) ON-LINE CONTROL OF AIRCRAFT, AIR TRAFFIC, AIRCRAFT NAVIGATION OR AIRCRAFT COMMUNICATIONS; OR (II) IN THE DESIGN, CONSTRUCTION, OPERATION OR MAINTENANCE OF ANY NUCLEAR FACILITY. WORLEY DISCLAIM ALL WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO WARRANTIES RELATED TO: NON-INFRINGEMENT, ACCURACY OR COMPLETENESS OF RESPONSES OR RESULTS, IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE . IN NO EVENT SHALL WORLEY BE LIABLE FOR ANY INDIRECT, INCIDENTAL, SPECIAL OR CONSEQUENTIAL DAMAGES OR FOR ANY DAMAGES WHATSOEVER (INCLUDING BUT NOT LIMITED TO DAMAGES FOR LOSS OF BUSINESS PROFITS, BUSINESS INTERRUPTION, LOSS OF BUSINESS INFORMATION, PERSONAL INJURY, LOSS OF PRIVACY OR OTHER PECUNIARY OR OTHER LOSS WHATSOEVER) ARISING OUT OF USE OR INABILITY TO USE THE SAFETY UNIT, EVEN IF ADVISED OF THE POSSIBILITY OF SUCH DAMAGES. REGARDLESS OF THE FORM OF ACTION, WORLEY AGGREGATE LIABILITY ARISING OUT OF OR RELATED TO THIS AGREEMENT SHALL NOT EXCEED THE TOTAL AMOUNT PAYABLE BY YOU UNDER THIS AGREEMENT. THE FOREGOING LIMITATIONS, EXCLUSIONS AND DISCLAIMERS SHALL APPLY TO THE MAXIMUM EXTENT ALLOWED BY APPLICABLE LAW. 3 www.worley.com.au/wecs 3 Introduction Lithium is the lightest metal on earth. It also has the greatest energy potential of any solid material. With this unique combination of light weight, high energy and temperature endurance, lithium is an ideal material for making batteries. But, because lithium is flammable, it requires careful handling during charging and discharging. Therefore lithium batteries must be controlled in voltage and temperature during their whole lifecycle. The Lithium Battery Safety Unit (LBSU-4-100) is designed to control the single cell voltages and watch the temperature of a Lithium Battery with a nominal voltage of 100V. 4 4.1 Description of the Hardware Structure of the Safety Unit The LBSU-4-100 consists of 4 measurement modules where each can control up to 7 cell voltages and 2 temperatures. The measurement modules are optically coupled and one of the modules has a master function. Every standard measurement module sends its data to the master module. The master module transmitts everey minute a set with the data of every measurement module to the RS232 interface. If any of the measurement modules detects an error, an error message is sent to the master module immediately. The master module then sends a message to the RS232 interface and shuts down the battery. Once the battery is shut down (load relay is open), you must fix the error and press the RESET button to restrat the safety unit. 4.2 Power Supply The measurement modules are powered by the cells that they are connected to. The minimum voltage is 6.5V (3 cells) and the maximum voltage is 30V (7 cells).The voltage at the measurement module is regulated with an on board DC/DC-Converter to a value of 5V. This is the reason, why the current consumption of the module is lower, the more cells are connected (approximately 8mA, when 7 cells are connected). 4 www.worley.com.au/wecs 4.3 Voltage Inputs For the measurement of the cell voltages a switched capcity is used. The single cells are one after the other switched to a capacitor via a multiplexer for a predefined time, so that the capacitor reaches the same voltage as the cell. After that the capacitor is cut off the cell and switched to the input of a A/D-Converter. The A/D-Converter is able to measure voltages from 0V up to 4.5V with an accuracy better than 1% (45mV). The single cells are connected to the measurement modules with a 8 wire module cable. At the one end of the cable there is a 9-pin female SUB-D connector, where the wires are connected in the following order to the SUB-D connector: Pin Nr 1 2 3 4 5 6 Color Black Brown Green Yellow Orange Violett 7 8 9 Blue Red n.c. At the other end of the cable there are 8 blank wires. By connecting this wires to the battery, there must be observed the following rules in order to prevent hazardous situations: For each wire there must be installed a fuse as near as possible at the battery The nominal value of the fuse must be between 0.5Amp...1Amp. The voltage drop over the fuses must be as small as possible (RFuse < 1Ohm), as this voltage reduces the measured value and therefore reduces accuracy of the measurement. Caution: The SUB-D connector must not be connected to the safety unit box during the cable is soldered to the battery. To connect 7 cells of a battery to a measurement module, you need 8 fuses and 1 module cable. Here is an example, how to connect the first 7 cells of a battery to a module cable (see also figure in Appendix A): 1. Connect one end of the first fuse to the minus pole of the first cell (this is also the minus pole of the battery). Then connect the black wire of the module cable to the other end of the fuse 2. Find the position, where the plus pole of the first cell and the minus pole of the second cell is connected. Connect one end of the second fuse to this connector. Then connect the brown wire of the module cable to the other end of the fuse 5 www.worley.com.au/wecs 3. Find the position, where the plus pole of the second cell and the minus pole of the third cell is connected. Connect one end of the third fuse to this connector. Then connect the green wire of the module cable to the other end of the fuse 4. Find the position, where the plus pole of the third cell and the minus pole of the fourth cell is connected. Connect one end of the fourth fuse to this connector. Then connect the yellow wire of the module cable to the other end of the fuse 5. Find the position, where the plus pole of the fourth cell and the minus pole of the fifth cell is connected. Connect one end of the fifth fuse to this connector. Then connect the orange wire of the module cable to the other end of the fuse 6. Find the position, where the plus pole of the fifth cell and the minus pole of the sixth cell is connected. Connect one end of the sixth fuse to this connector. Then connect the violett wire of the module cable to the other end of the fuse 7. Find the position, where the plus pole of the sixth cell and the minus pole of the seventh cell is connected. Connect one end of the seventh fuse to this connector. Then connect the blue wire of the module cable to the other end of the fuse 8. Find the position, where the plus pole of the seventh cell and the minus pole of the eighth cell is connected. Connect one end of the eighth fuse to this connector. Then connect the red wire of the module cable to the other end of the fuse Now the first module cable is completely connected. With the second module cable you must start at that point, where you stopped with the first module cable (the position, where the plus pole of the seventh cell and the minus pole of the eighth cell is connected) and repeat the procedure described above. The third module cable is connected in the same way. But there is an exception to the fourth module cable. Here only the remaining 6 cells are connected and the remaining red wire of the module cable is left blank (cut off, or isolate this wire). After all the module cables are wired with the battery, they can be plugged at the four 9 pin male SUB-D connectors at the safety unit box, labeled with Module1, Module2, Module3 and Module4. The software at the measurement modules will use the following numbering scheme: Cell1...Cell7 at measurement module 1 Cell8...Cell14 at measurement module 2 Cell15...Cell21 at measurement module 3 Cell22...Cell27 at measurement module 4 6 www.worley.com.au/wecs After all 4 cables are connected to the box, you should press the RESET button at the front panel. By doing this, all measurement modules begin working properly. 4.4 Temperature Sensors The temperature sensors are already completely connected to the safety unit box. Place the sensors at that points of the battery, where the highest temperatures are estimated. Although it would be possible to measure 8 temperatures with 4 measurement modules, in the present case only 4 sensors are connected (T3, T4, T5 and T6). This is the reason, why T1, T2, T7 and T8 will always be displayed with 0.0DegC in the terminal program window. The accuracy of the temperature sensor is typically ±1°C at 25°C and ±2°C over the total rated temperature range between +5°C and +85°C. The value of the temperature sensor is sampled with a resolution of 10bits at the A/D-converter. The battery will be shut down, when the temperature at any sensor rises above 50.0°C. 4.5 Reset Output At the lower side of the safety unit box, near the 9 pin SUB-D connectors, there is a 2.5mm connector labeled RESET. Here you can plug a 2 wire cable to reset the safety unit remotely. To use this feature, you must prepare the cable. The plug is shipped with the box. At the plug you can solder two wires and shield. If you use a shielded cable you must solder one wire to one pin and the other wire to the remaining pin. It doesn’t make any difference, which wire is soldered to which pin, but the shield must be soldered to the outermost contact. If you use an unshielded cable, leave this contact blank. At the other side of the cable you must connect a push-button switch (normally open) with two pins. Solder one pin to one wire of the cable and the remaining pin to the second wire. If you have a good (strong) ground potential near the push-button, connect the shield to this potential. But if you do this, you must guarantee, that the voltage between ground potential and minus pole of the battery is always less than 10V. The length of the cable should be as short as possible (let’s say not more than 4m), because noisy electromagnetic environment may cause malfunction at the safety unit. 7 www.worley.com.au/wecs 4.6 Load Relay Output Near the RESET plug at the lower side of the safety unit, there is the plug for the load relay. It is labeled with „Relay“. This output must be used to shut down the battery (stop charging or discharging). This output is optically isolated. This means, that it has no electric connection to any potential inside the safety unit box. The battery must be shut down with „normally open“ contacts of an external load relay, that can cut the current between battery and load. The coil of the load relay must be equipped with a rectifier, that is able to clamp the inductive voltage peaks, when the relay is shut down. To understand, how to connect the relay, see also the figure in Appendix A. The coil of the relay must be connected to the plus pole of an external power supply at one end. The other end of the coil must be soldered to one wire of the cable that leads to the relay output connector. The other wire of the cable must be connected to the minus pole of the power supply for the coil of the load relay. At the other side of the cable the cinch connector has to be soldered. The wire with the higher voltage has to be soldered to the inner pin and the wire with the lower voltage (this one that leads to the minus pole of the power supply) to the outer pin. To shut down the battery, the safety unit will cut the current through the coil of the load relay and so the relay will no longer be activated and the load current will be cut. This also means, that it is not possible to activate the battery if the load relay output is disconnected. 4.7 Serial Interface (RS232) Behind the Relay and RESET plug at the bottom side of the safety unit, there is the 9 pin female connector for the serial interface, labeled with RS232. Here you can plug a standard 9 pin PC serial cable. The serial interface is unidirectional, this means, that data is only transmitted from the safety unit to the computer. Sending data from computer to safety unit will have no effect. Use the following settings at the PC, to make data transmission working properly. Baudrate 9600 Databits 8 Parity None Stopbits 1 Protocol None In this version the serial interface is just used for displaying data and status messages. For displaying the data at the computer, you can use any standard terminal program (i.e. Hyper 8 www.worley.com.au/wecs Terminal© with Windows© operating system). During normal operation every minute a set of data is transmitted from safety unit to PC. The dataset includes 28 cell voltages and 8 temperature values. Here is an example for one dataset. C1= 4026mV; C2= 3674mV; C3= 3687mV; C4= 3682mV; C5= 3700mV; C6= 3696mV; C7= 3678mV; C8= 3788mV; C9= 3744mV; C10= 3696mV; C11= 3700mV; C12= 3748mV; C13= 3722mV; C14= 3748mV; C15= 3960mV; C16= 3674mV; C17= 3704mV; C18= 3726mV; C19= 3704mV; C20= 3700mV; C21= 3682mV; C22= 3572mV; C23= 3220mV; C24= 3198mV; C25= 3220mV; C26= 3203mV; C27= 3194mV; C28= 0mV; T1= 0.0DegC; T2= 0.0DegC; T3= 25.8DegC; T4= 26.2DegC; T5= 26.1DegC; T6= 26.1DegC; T7= 0.0DegC; T8= 0.0DegC; Each cell is shown with cell number and voltage value in millivolts. C1= 4026mV means, that cell number one has a voltage of 4.026V. Cell number 28 will always be displayed with 0mV, as no cell is connected to input 7 of measurement module 4 (4*7=28). Below the voltage values, the temperature values are displayed. T3= 25.8DegC means, that at temperature sensor 3 a temperature of 25.8 degrees centigrate was measured. 4.8 Front Panel At the front panel of the safety unit box, there are attached 3 LEDs and a push button. The push button is for resetting the complete safety unit. By pressing this button every 4 measurement modules inside the box are restarted. This button is connected parallel to the RESET-Output described above, and therefore has the identical function. The first LED (red color) indicates differnt conditions. When this LED is blinking, everthing is ok and the battery is working properly. When the red LED is continously on, there is a fault at one of the 4 measurement modules. In this case there will be an error message transmitted to the computer. Two different messages are possible: 1. #Fault at module number X, battery shut down !!! Please check and press RESET In this case the module with number X sends no more data to the master module. There is probably a technical defect at the module, or no, respectively too less cells are connected to the module. The battery is shut down and all measurement modules are powered down, to reduce current consumption. If you can fix the problem, the modules can be restrated by pressing the RESET button. 2. #Undefined ERROR occured, Battery shut down !!! Please press RESET to restart measurement modules !!! 9 www.worley.com.au/wecs In this case the internal data transmission between the measurement modules was bad for several times. The load relay is opened, but the modules continue measuring the cell voltages and temperatures. The reason for this error may be a noisy electromagnetic environment. Postioning the cables or the safety unit box on another place may fix this problem. To restart the safety unit press the RESET button. The second LED (yellow color) indicates OVERVOLTAGE. When this LED is continously on, there was measured a voltage of more than 4.2V at any of the connected cells. In this case the battery is shut down and all measurement modules are powered down to reduce current consumption. Also the following error message is transmitted to the computer: #Overvoltage at Module Number X, Battery shut down !!! Where X is the number of the measurement module, that transmitted the error message. To find the cell that caused the error message, you must check the last data set transmitted to the computer. Here you must check the voltages of the 7 cells connected to the measurement module with the number transmitted with the error message. The voltage that is nearest to 4.2V belongs to that cell, that caused the battery shut down. You will not be able to restart the safety unit (by pressing the RESET button), until all cell voltages at the battery are below 4.2V. The third LED (yellow color) indicates UNDERVOLTAGE. When this LED is continously on, there is a voltage of less than 2.7V at any of the connected cells. In this case the battery is shut down and all measurement modules are powered down to reduce current consumption. Also the following error message is transmitted to the computer: #Undervoltage at Module Number X, Battery shut down !!! Where X is the number of the measurement module, that transmitted the error message. To find the cell that caused the error message, you must check the last data set transmitted to the computer. Here you must check the voltages of the 7 cells connected to the measurement module with the number transmitted with the error message. The voltage that is nearest to 2.7V belongs to that cell, that caused the battery shut down. You will not be able to restart the safety unit (by pressing the RESET button), until all cell voltages at the battery are over 2.7V. Both yellow LEDs are continuously on, indicates OVERTEMPERATURE. In this case one of the temperature sensors measured a temperature of more than 50 degrees centigrade. The battery is shut down and all measurement modules are powered down to reduce current consumption. Also the following error message is transmitted to the computer: 10 www.worley.com.au/wecs #Overtemperature at Module Number X, Battery shut down !!! Where X is the number of the measurement module, that transmitted the error message. To find the number of the sensor, that caused the error message, you must check the last data set transmitted to the computer. The temperature that is nearest to 50°C is that one, that caused the battery shut down. You will not be able to restart the safety unit (by pressing the RESET button), until all temperatures at the battery are below 50°C. First LED (red) Second LED (yellow) Third LED (yellow) Push-Button 11 www.worley.com.au/wecs 5 Technical Data Cell voltage inputs (7 per module) Temperature (2 per module) Overvoltage Undervoltage Overtemperature Power supply Current on/off output Operating temperature Range Current consumption Resolution 10 bits Voltage range full scale +4.5V Resolution 10 bits Temperature range 5°C to 75°C Cell voltage ≥ 4.2V Cell voltage ≤ 2.7V Temperature at sensor ≥ 50°C From battery, 6.5V min. per module 30V max. per module Plug for coil of external relay , current over plug. 100mA max 8mA max. with 7 cells connected 4mA in power save mode 0°C – 70°C 12 www.worley.com.au/wecs 6 Appendix A Titel: EAGLE Draw ing P:/3130 271Edison/Mes smodul/LithiumBSM/CellConnect.sc h Ers tellt v on: EAGLE Vors chau: Dies e EPS-Grafik w urde nicht ges peic hert mit einer enthaltenen Vorsc hau. Kommentar: Dies e EPS-Grafik w ird an einen PostScript-Druc ker gedruc kt, aber nic ht an andere Druckertypen. 13 www.worley.com.au/wecs