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May 2016
Evolion® 3.9 kWh
Installation and operation instruction sheet
1. Introduction
The Evolion® is a Li-ion battery system that includes large format Li-ion cells and
necessary electronics for automatic interruptions or regulated operations when un-safe
limit is exceeded and detected.
This sheet is a quick start guide. It describes how to install and operate the Evolion®
in a legacy battery mode, i.e., with no RS485/Modbus communication connected.
Within this sheet, the necessary tasks are noted with Ev#’s and they are in order that
they should be conducted. Use the Evolion® 3.9 kWh historical data sheet (included)
for records. Make sure to read the Evolion® 3.9 kWh Installation and Operation User
Manual (UM), the Evolion® 3.9 kWh Technical Manual (TM) and the Evolion® Toolbox
Software User Manual (CM). Check with your local Saft Representative for more details.
2. Safety
4. Unpacking and Inspection
Misusing the Evolion® may cause an event
like cell venting, overheating or igniting.
■■ Read these instructions fully before
installing and operating the Evolion®.
■■ Do not short-circuit the power
terminals.
■■ Do not reverse connect the power
cables to the charger.
■■ Do not disassemble the unit.
■■ Do not drop the unit.
■■ Do not immerse the unit.
■■ Do not expose the unit to fire or
temperature higher than 80°C
(176°F).
■■ Connect only to telecom power
systems/rectifiers with a maximum
rated output of 60 V.
■■ Refer to the Battery Information
Sheet or BIS (included) for
emergency response procedures
and personal protective equipment
in case of an abnormal event.
■■ If smoke is emitted from the
module, stay clear of the smoke and
evacuate the area immediately.
■■ For normal handling and operation
according to this installation and
operation sheet, no personal
protective equipment is required.
The Evolion® is packaged in accordance
with UN3480 Class 9 Group 2. See
Figure 1 for lifting instructions.
Check that all items are
received.
Table 1
If items were not received or if anything
was damaged do not install the module
and contact your local Saft representative.
Ev2 Study Evolion® features.
Figure 3
Check the state after
Ev3 receiving and before
storage or installation.
Figure 1
Figure 4
Table 2
Always keep the Evolion® module and its
kit in its original packaging, together.
5. Storage
Store the battery in its original packaging.
• 15°C to 35°C (59°F to 95°F).
• No direct sunlight, rain or flooding
• Up to 1 year without refreshing charge
After 6 months, check the
Ev4 state once per month in
storage.
Table 2
Figure 4
IMPORTANT: Never leave the Evolion®
ON when it is not in use. The internal
electronics will self-discharge the cells
to a low voltage alarm level which may
render the module un-usable.
6. Transportation
3. Tools
These tools are needed and are not
provided.
Tool
Ev1
Use
Voltage and fuse continuity
Front cover removal/
replacement
Grounding point screw
Power and fuse terminals
External case notations
BMST reset button
Follow the necessary transportation
rules for Li-ion batteries by consulting
with your company’s standard practice
and your local transportation regulations.
• Use the original packaging or equivalent.
• Secure the Evolion® in place
• The Evolion® must be OFF.
7. Installation
Before installing, make sure the right
number of Evolion® you will connect to
one bus is properly sized. Consult with
your local Saft Representative or consult
with the Evolion® TM.
Size the proper number
Ev5 of Evolion® to connect to
one bus.
Evolion®
TM
Before installing, double check the state
of each Evolion®.
Ev6
Check for a maximum of
2 V difference allowed
between modules that will
operate on the same bus.
Figure 1
Figure 4
If modules have more than 2 V difference
equalizing the Evolion® modules is
necessary, refer to the Evolion® UM.
For modules that will
operate on the same bus,
set each with a unique
Ev7
Node ID, manually between
1 to 4 or using the Evolion®
Toolbox Software.
Figure 6
(manual)
or
Evolion®
CM
(software)
The Evolion® can be installed and
operated in Network Telecommunication
Facilities including un-manned OSP. The
Evolion® can be placed on shelves or in
battery compartments with the following
characteristics.
• IP54 (NEMA3) or higher
• -40°C to 75°C (-40°F to 167°F)
• 95% RH max. (non-condensing)
• Up to 3000 meters (9843 feet)
• No blocking the heat sink and vent ports
• Right side up or sideways
Ev8
Connect the Evolion®
modules.
Ev9 Power ON
Figure 8
Figure 9
Figure 10
8. Operation/Maintenance
The Evolion® provides un-interrupted standby
power anytime the AC power supply is
OFF. Continue trouble free operation in
accordance with these instructions.
The Evolion® requires no maintenance,
but periodically checking it during other
site routines is recommended.
• LED state (Table 3 and 9.
Troubleshooting)
• SOC and SOH (Table 2)
• Heat sink area un-obstructed
• Clean any excessive dirt build-up using a
nonmetallic brush or a dry or damp cloth.
• Do not use any cleaning solvents or soaps.
• Do not immerse, bathe or hose off the
Evolion®.
9. Troubleshooting
When the Evolion® is in service, observe
the LED's. See Table 3 for operation
LED state.
LED
Refer to
state
D
Evolion® TM, Appendix E
E
Evolion® TM, Appendix E; Figure 11
IMPORTANT: The Evolion® must
be re-charged within 2 weeks after
Alarm #36 was activated or the
module may be rendered useless.
G
Figure 11
Figure 1. Lifting
Table 3. Operating LED legend (no push button)
#
LED state
Description
A
Floating or Forbidden Charge
Mode (warning alarm #11)
B
Charging in fast charge mode
or regulated charge mode
C
Discharging
Only use the lifting points.
NOTE: The Evolion® weighs 30 kg (66 lbs).
IMPORTANT: Using other than the lifting points shown may
cause irreparable damage.
D
Warning alarm
(continues normal operation),
See 9. Troubleshooting
Table 1. Included with the Evolion® kit, 782674 (-11)
F
Bootloader mode
(only when used with
Evolion® Toolbox Software)
G
Sleep or OFF
1
P/N
782672XX
(Note 1)
Description
Qty
Evolion® 3.9 kWh
module
(Note 1)
E
(Note 1)
Major alarm (disconnected),
See 9. Troubleshooting
Illustration
Note 1:To diagnose the alarms, use the Evolion® Toolbox Software
available in the Evolion® Communication Kit (772309)
1
Figure 3. Evolion® features
781081
Fuse, replaceable,
spare
1
772516
Power cable, 8
GA., ¼” ring lugs,
positive, 1 meter
1
Power cable, 8
GA., ¼” ring lugs,
negative, 1 meter
1
772518
Comm. cable, RJ45
male (x2), 1 meter
1
773455
Resistor cap, RJ45
male
1
(Note 2)
772517
(Note 2)
Note 1:The kit variant is indicated by the”-XX”. The standard kit is
shown in Table 1 is the -11 variant.
Note 2:The power cable assembly and part number may vary based on
the kit variant.
Table 2. SOC/SOH LED legend (after pushing button)
#
LED state
SOC
SOH
(Push < 3 sec.)
(LED’s steady)
(Push ≥ 3 sec.)
(LED’s flashing)
1
< 25% SOC
charge is
necessary
< 25% SOH
< 77% Ah
avail.
2
≥ 25% SOC
Store
(7 months)
or operate
≥ 25% SOH
≥ 77% Ah
avail.
3
≥ 50% SOC
Store
(13 months)
or operate
≥ 50% SOH
≥ 85% Ah
avail.
4
≥ 75% SOC
Store
(20 months)
or operate
≥ 75% SOH
≥ 92% Ah
avail.
ON/OFF push button, 2 seconds ON – 4 seconds OFF
SOC (State of Charge) and SOH (State of Health) push
button, see Table 2
3 LED1 (left), LED2, LED3 and LED4 (right), see Table 2
and 3
4 Positive power terminal, M6 hex head bolt
5 Negative power terminal, M6 hex head bolt
6 Grounding point, M3 socket head screw
7 Front cover, 3.5 mm x 12 mm, self threading, torx head
screw
8 BMST micro-processor reset button
9 Replaceable fuse (not shown) and cover, use only 771285
10 RJ45 (female) – 2 jacks with pins connected in parallel
1
2
Pin
Type
1
RS485+
2
4
RS485Ground (isolated from power
terminals)
Wake up (+12 V to ground)
5
Not used
6
Not used
7
Dry contact alarm loop
8
Dry contact alarm loop
3
Figure 4. Checking the State
Figure 6 Steps (refer to illustration and tools)
CAUTION: Make sure to disconnect the power cables before
conducting these steps.
Turn OFF the Evolion®
2 Press and hold the SOC/
SOH button and ON/OFF
button simultaneously for
2 seconds.
3 The current Node ID will be
displayed. See Table F6.
4 To change the Node ID,
press the SOC/SOH button
until the LED indicates a
Node ID between 1 and 4.
See Table F6.
5 Press the ON/OFF button
for 4 seconds to turn OFF;
the new Node ID is now set.
6 Scribe the Node ID on the
outside in a visible location.
1
Figure 4 Steps (refer to illustration and tools)
1 Press ON/OFF button for 2 seconds and allow the self-test
to complete. Record the Operating LED state (see Table 3).
CAUTION: When ON, the battery voltage is connected to the
power terminals.
2 Press the SOC/SOH button (See Table 2).
3 Observe and note the LED state for SOC and SOH (See
Table 2).
4 Remove cover and measure and note the terminal
voltage. Replace cover.
5 Press ON/OFF button for 4 seconds to turn OFF the Evolion®.
The Evolion® is now ready for continued storage or service.
Table F6. Node ID#
LED
ID#
1
2
3
4
>4
(Note 1)
Note 1:To set a Node ID higher
than 4, use the Evolion®
Toolbox Software.
The Evolion® is now ready for continued storage or service.
Figure 8. Connections
Figure 5. Refreshing charge
Figure 5 Steps
1 Connect the power terminals to a telecom rectifier
according to Figure 8.
NOTE: If the voltage is within 0.5 V between the modules,
paralleling and charging more than one module is OK. See
Figure 4 to check module voltage.
2 Before applying power, set the rectifier output voltage
according the Table F5 and the maximum output current
to 21 Amps per Evolion®.
3 Power ON and start charging according to Figure 10.
4 Continue charging for the minimum amount of time
according to Table F5.
5 Turn OFF the rectifier output power and then turn OFF
the Evolion®.
The Evolion® is now ready for continued storage or service.
Table F5. Charging guide
Max. V
set-point
Chg hours
45% (1 year more storage)
50.5 V ±1.0%
2.5
100% (to put in service)
56.0 V ±1.0%
4.5
To set %SOC
(Note 1)
Note 1: Based on 21 Amps per Evolion and 0% SOC at the start of charge.
®
Figure 6. Manual Node ID setting (ID # from 1 to 4)
Figure 8 Steps (refer to illustration and tools)
CAUTION: Do not conduct these steps if any Evolion® has more
than 2 V difference. The fuse or power board may be overloaded.
IMPORTANT: Make sure all Evolion® modules are OFF before starting.
1 Make sure the rectifier battery output breakers are open
or disconnected so the power bus is not live with power.
IMPORTANT: Never turn the Evolion® ON using the ON/OFF
button once the power cables are connected to the power
bus to avoid breaking a fuse due to pre-charging a capacitor.
IMPORTANT: Never connect the Evolion® in series.
2 Remove the front cover and connect all the Evolion® power
cables provided (772516, 772517). Replace the front
cover after torqueing the terminals.
NOTE: The recommended terminal torque is 6 N-m
(53 in-lbs) unless otherwise noted on the Evolion®.
NOTE: Either power terminal can connect and operate on
a Common Bonding Network (CBN) or an Isolated Bonding
Network (IBN).
3 Connect all communication cables provided (772518)
between each Evolion®.
4 Connect the RJ45 resistor cap provided (773455).
5 Connect all grounding points on the heat sink face.
NOTE: It is not necessary to ground the heat sink face to function.
The Evolion® modules are now ready to connect communication
according to Figure 9 and Power ON according to Figure 10.
SHUTDOWN procedure:
a Open the output breaker (1)
b Turn OFF each Evolion® using the ON/OFF button.
c Disconnect cables.
Figure 9. Connecting Communication to the Application
Figure 10. Powering ON
A
B
Table 5. Rectifier settings
Figure 10 Steps (refer to illustration and tools)
Make sure the AC power is ON and the rectifier controller is
operating normally.
Make sure the Evolion® modules are turned OFF.
1 Turn ON the rectifier output power. The Evolion® modules
will automatically wake up and begin charging after a few
seconds.
2 Observe the LED’s (see Table 3).
The Evolion® is now in service.
IMPORTANT: These setting are necessary in order to avoid
rendering the Evolion® unusable and requiring a site intervention.
Figure 11. Fuse Check/Replace and BMST reset
Figure 9 Steps (refer to illustration and tools)
1 Prepare a communication cable to connect to the application.
2 Color match the pins according to 568A or 568B cable.
3 Connect the prepared cable ends to the application.
The Evolion® is now ready for communication and Figure 10.
#
Type
Value
a.
Single level charge voltage
56.0 V ± 0.5% (all charge
operations) (Note 1)
b.
Temp. Comp. V. (TCV)
Turned OFF or Disabled
c.
Max. re-charge current
See Table 6
d.
Ramp in voltage
Longest setting up to
3 minutes
e.
Default rectifier voltage
42 V to 46 V
f.
Low Voltage Disconnect
45 V (≤ 12 in parallel)
46 V (> 12 in parallel)
Note 1:The Evolion® operates normally between 49.5 V to 56.0 V. The
highest %SOC is reduced by 10% for each 1 V below 56.0 V.
Table 6. Maximum Re-charge Current Settings
Max. per
Evolion® (Note 1)
Duty
To avoid
overheating
To avoid charge
regulated mode
4x cycles per day or more
16 A
3x to 4x cycles per day
21 A
2x to 3x cycles per day
24 A
1x to 2x cycles per day
32 A
1x cycle per day or less
21 A
Note 1:Make sure to always operate at less than 0.85xIMR or less to
avoid charge regulated mode (see Evolion® TM).
Saft
Industrial Battery Group
12, rue Sadi Carnot
93170 Bagnolet - France
Tel :+33 (0)1 49 93 19 18
Fax:+33 (0)1 49 93 19 64
Figure 11 Steps (refer to illustration and tools)
CAUTION: Make sure the Evolion® is OFF and disconnected
before conducting these steps.
1 Remove the front cover.
2 Remove the fuse cover.
3 Check the fuse continuity (close to zero ohms = good fuse);
replace fuse (781081) as necessary. Replace fuse cover
4 Turn ON the Evolion®
5 Check LED state (Table 3) and push BMST reset button
as necessary to clear alarms.
6 Turn OFF the Evolion®.
The Evolion® is now ready for storage or service.
Doc. Nº 21952-0516-2
Edition: May 2016
Data in this document is subject to change without
notice and becomes contractual only after written
confirmation.
Société par Actions Simplifiée au capital de
31 944 000 €
RCS Bobigny B 383 703 873
www.saftbatteries.com
Produced in the UK by Arthur Associates Limited
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