USER MANUAL Maxwell Technologies® BOOSTCAP® Ultracapacitor Energy Storage Modules for Low Duty Cycle Applications Models: BMOD0125 P064 B02 BMOD0094 P075 B02 Document #1014204 Notice: The products described herein are covered by one or more of the following patents: 7307830, 7203056, 7027290, 7352558, 7295423, 7090946, 7508651, 7492571, 7342770, 6643119, 7384433, 7147674, 7317609, 7495349, 7102877 © 2008-2011 Maxwell Technologies, Inc. ® Notice: The products described herein are covered by one or more of the following patents: 7307830, 7203056, 7027290, 7352558, 7295423, 7090946, 7508651, 7492571, 7342770, 6643119, 7384433, 7147674, 7317609, 7495349, 7102877 © 2008-2011 Maxwell Technologies, Inc. ® WARNING DANGER – HIGH VOLTAGE HAZARD! Never touch the power terminals as the module can be charged and cause fatal electrical shocks. Always check that the module is fully discharged before manipulating the module. For more information about the discharge procedure, please refer to Paragraph 7. 1 Introduction Low duty cycle energy storage module is a self-contained energy storage device with multiple cells electrically connected and contained in a plastic housing. Individual modules may be connected in series to obtain higher operating voltages, in parallel to provide additional energy storage, or a combination of series/parallel arrangements for higher voltages and energy. Only modules of the same model should be interconnected. Passive balancing and thermal monitoring is incorporated into the module, the latter being accessible through a standard connector. The module enclosure consists of top and bottom highly resistant ABS shells, sheet metal sides, and a thick top plate on which the monitoring connector is mounted. The enclosure is not sealed but compliant per IP54 and requires no maintenance. Module temperature can be monitored by accessing the output of an internally mounted PT100 Thermistor through the monitoring connector. 2 Unpacking Inspect the shipping box for signs of damage prior to unpacking the module. Damage to the shipping box or module should be reported to the carrier immediately. Remove the module from the shipping box by lifting the module straight up. Each module can be lifted by hand by one person. Retain the shipping materials until the unit has been inspected and is determined to be operational. The original shipping materials are approved for both air and ground shipment. Make sure that the shipping container(s) contain(s) the following: 1) Energy Module 2) User’s Manual If the unit is found to be defective or any parts are missing, contact Maxwell Technologies. A Return Material Authorization (RMA) number must be issued prior to returning the unit for repair or replacement. There are no other mating connector or accessory kits available for these units. User Manual – Low Duty Cycle Modules – Doc. no.: 1014204.3 © 2008-2010 Maxwell Technologies, Inc. ® Page 1 3 Installation 3.1 Mechanical The module can be mounted in 2 orientations and requires the proper hardware to be used. The 2 supported orientations are: - Horizontal, with connector on the top Vertical, on the longer side. For this orientation, the module needs to be bolted to a supporting side wall Refer to Figure 1.1 and 1.2 below for overall module dimensions and mounting hole locations. The mounting plate on the top of the module is designed to support attachment of the module to an electrical system or enclosure. In order to properly secure the module to a base plate, use 4 (four) screws, M6, minimum 200 mm long, allowing for a minimum of 10 mm thread engagement in the base plate. These mounting screws must be 18-8 stainless steel or stronger, torqued to a recommended 12 Nm, and must include flat washers and locking devices. Longer screws may be required if using through-holes and nuts. NOTE: These screws are application specific and thus NOT included with the module. The temperature monitoring mating connector is not included with module. The mating connector can be sourced as follows: BMOD0094 P075 module Manufacturer: Harting® www.harting.de. Quantity 1 3 1 Part Number 09 36 008 3101 09 15 000 622x 09 37 003 1440 Or 19 37 003 1440 Description mating insert mating pins hood (heavy duty) hood (std) BMOD0125 P064 module Manufacturer: Molex MX150L Quantity 1 2 Part Number 19418 19420 Description Receptacle Female terminal, 14-22AWG When installing multiple modules in series or parallel configurations, leave 25mm clearance (minimum) between modules. Refer to section 3.2.1 for more electrical information on series and parallel configurations. Mounting dimensions and locations are shown in Figures 1 and 2. Please refer to the datasheet for the most up to date specifications. User Manual – Low Duty Cycle Modules – Doc. no.: 1014204.3 Document no.: 1014204.2 ©2008-2010 Maxwell Technologies, Inc.® Page 2 Figure 1. a) 75V/94F Module Dimensions Figure 2. b) 64V/125F Module Dimensions. Figure 3. a) 75V Module mounting b) 64V Module mounting User Manual – Low Duty Cycle Modules – Doc. no.: 1014204.3 Document no.: 1014204.2 ©2008-2010 Maxwell Technologies, Inc.® Page 3 3.2 Electrical WARNING To avoid arcing or sparking, the energy storage module should be in a discharged state and the system power disconnected during installation. The module is shipped discharged. The shorting wire should be removed just prior to making electrical connections. For more information about the discharge procedure, please refer to Paragraph 7. To provide the lowest possible equivalent series resistance (ESRDC), the high power current path within the module is not fused. Care should be taken within the application to prevent excessive current flow. Excessive current and/or abnormal duty cycle will result in overheating the module and may cause irreparable damage. Please consult the specific data sheet for each module for current and duty cycle capabilities. The module features a passive balancing system that consists of one resistor in parallel with each cell. 3.2.1 Power Connection 3.2.1.1 Output Terminal Posts The output terminals of the module consist of internally threaded aluminum posts. Maximum thread depth (bolt depth) is 15 mm. They are designed to connect directly to a ring lug or a bus bar appropriately sized for the application current. Apply a layer of antioxidant joint compound between the mating surfaces (high conductivity aluminum-aluminum, for example, Noalox® AntiOxidant Compound available from IDEAL; there are many other vendors that supply equivalent compounds). The positive terminal is threaded for M8 x1.25 steel bolts. The negative terminal is threaded for M10 x 1.5 steel bolts. Wave washers are required to ensure long term, reliable connections. When applying torque to the terminals, it is recommended to use the maximum torque for the M8 (20 Nm) and for the M10 (30 Nm) bolts and for aluminum threads. Anti-rotation features within the module limit the potential for damage to the terminals when applying torque to the bolts. The energy storage modules have a low ESR. As a result, the resistance of the wires connecting the energy storage module to the application can easily exceed the ESR of the module. Connection of modules in series or parallel should utilize the same gauge wire (or equivalent bus bar) as determined for final output connections. When connecting in series connect the positive output terminal of one module to the negative output terminal of the next module. When connecting in parallel connect the positive and negative output terminals of one module or string to the positive and negative output terminals, respectively, of the next module or string. When several modules are connected in series for operating at higher voltage, care must be taken to ensure proper creepage and clearance distances in compliance with safety standards for electrical equipment. When connecting modules in combination of series and parallel, please consult the local Maxwell Technologies application engineer. It is recommended to install covers over the power terminals to provide adequate isolation at the terminal level. These terminal covers are cable specific and are not included with the module. User Manual – Low Duty Cycle Modules – Doc. no.: 1014204.3 Document no.: 1014204.2 ©2008-2010 Maxwell Technologies, Inc.® Page 4 3.2.2 Monitor Connection A single, 8-pin connector on the top panel of the energy module carries signals for temperature monitoring. Figure 1.3 shows the pin assignment on the 8-pin connector for the 75V module and the 2-pin connector for the 64V module.. Figure 4. Harting connector pinout. Figure 5. Molex connector pinout. Table 1. Pin assignment monitor connector. Pin Description 75V/94F 64V/125F 1 N/A RTD lead 1 or 2 2 N/A RTD lead 2 or 1 3 RTD lead 1 or 2 4 RTD lead 2 or 1 5-8 N/A 3.2.2.1 Temperature Monitoring The module uses a temperature sensor within the module at a location which is representative of the cell population temperature. The temperature output is via a PT100 resistance temperature device (RTD). The resistance of the sensor varies with temperature to provide the internal temperature of the module. The resistance measured through the sensor translates to temperature according to the chart in Table 2. (Device: Minco S17624PDYT20B, www.minco.com.) Table 2. RTD function diagram: Resistance versus Temperature. -1 -2 -3 -4 -5 -6 -7 -8 -9 -30 88.2217 87.8271 87.4325 87.0377 86.6428 86.2478 85.8526 85.4573 85.0619 84.6663 -20 92.1599 91.7666 91.3732 90.9797 90.5861 90.1923 89.7985 89.4044 89.0103 88.6160 -10 96.0859 95.6938 95.3016 94.9093 94.5169 94.1244 93.7317 93.3390 92.9461 92.5530 0 100.000 99.6091 99.2181 98.8270 98.4358 98.0444 97.6529 97.2613 96.8696 96.4778 +1 +2 +3 +4 +5 +6 +7 +8 +9 Temp°°C 0 -40 84.2707 Temp°°C 0 0 100.000 100.3908 100.7814 101.1720 101.5624 101.9527 102.3429 102.7330 103.1229 103.5128 10 103.9025 104.2921 104.6816 105.0710 105.4603 105.8495 106.2385 106.6274 107.0162 107.4049 20 107.7935 108.1820 108.5703 108.9585 109.3467 109.7347 110.1225 110.5103 110.8980 111.2855 30 111.6729 112.0602 112.4474 112.8345 113.2215 113.6083 113.9950 114.3817 114.7681 115.1545 40 115.5408 115.9270 116.3130 116.6989 117.0847 117.4704 117.8560 118.2414 118.6268 119.0120 50 119.3971 119.7821 120.1670 120.5518 120.9364 121.3210 121.7054 122.0897 122.4739 122.8579 60 123.2419 123.6257 124.0095 124.3931 124.7766 125.1600 125.5432 125.9264 126.3094 126.6923 70 127.0751 User Manual – Low Duty Cycle Modules – Doc. no.: 1014204.3 Document no.: 1014204.2 ©2008-2010 Maxwell Technologies, Inc.® Page 5 4 Thermal Performance Low internal resistance of the energy storage modules results in relatively low internal heat generation within the modules during use. However, the module is designed for UPS/backup and other low duty cycle energy operations only and not for high duty cycle operations. Sufficient time needs to be allowed between cycles, depending on operating voltage, current, outdoor and module temperatures. For this reason, it is very important to monitor the module temperature through the monitoring connector. 5 Accessories There are no accessories available for this product. 6 Operation The module should only be operated within specified voltage and temperature ratings. Determine whether current limiting is necessary on input/output based on current ratings of ancillary devices. Observe polarity indicated on module. 7 Safety WARNING DANGER – HIGH VOLTAGE HAZARD! Never touch the power terminals as the module can be charged and cause fatal electrical shocks. Always check that the module is fully discharged before manipulating the module. For more information about the discharge procedure, please refer to Paragraph 7. The unit is shipped with a shorting wire across the terminals. Do not remove this wire until the unit is placed into operation. Do not operate unit above specified voltage. Do not operate unit above specified temperature rating. Do not touch terminals with conductors while charged. Serious burns, shock, or material fusing may occur. Protect surrounding electrical components from incidental contact. Provide sufficient electrical isolation when working above 50 V DC. Prior to installation on and removal from the equipment, it is mandatory to fully discharge the module. Please proceed as follows to discharge the module: 1) Using a voltmeter, measure the voltage between the 2 terminals. User Manual – Low Duty Cycle Modules – Doc. no.: 1014204.3 Document no.: 1014204.2 ©2008-2010 Maxwell Technologies, Inc.® Page 6 2) If the module voltage is above 2V, you will need to connect a resistor pack (not supplied with the module) between the terminals. Proper care needs to be taken in the design and construction of such a dissipative pack. For example, at 75V, for a 2 Ohm pack, the module will be discharged with a current of 37.5A and will take 10-15 minutes to fully discharge. However, in this case, the heat/power dissipated in the resistor pack will be ~ 1.4kW. The resistor pack will need to be sized and provided with suitable cooling to handle this power dissipation. Additionally, proper enclosure or other packaging is necessary to ensure safety. In all cases, proper design of the dissipative resistor pack is necessary. 3) If the voltage is under 2V, the module is now considered safe for manipulation. However due to the low internal series resistance, high current can flow if the terminals are short circuited. Therefore specific care should still be taken. 8 Maintenance Prior to cable installation or removal, or any other handling, ensure that the energy storage module is completely discharged in a safe manner. The stored energy and the voltage levels may be lethal if mishandling occurs. 9 Storage The module can be stored in the original package, discharged, in a dry place. Observe the maximum storage temperature as stated in the specifications. Discharge used modules prior to stock or shipment. 10 Disposal Do not dispose of module in trash. Dispose of according to local regulations for electronic waste. 11 Specifications Refer to data sheets for specifications for each specific product. User Manual – Low Duty Cycle Modules – Doc. no.: 1014204.3 Document no.: 1014204.2 ©2008-2010 Maxwell Technologies, Inc.® Page 7 Contact Information: Maxwell Technologies, Inc. Global Headquarters 5271 Viewridge Ct, Suite 100 San Diego, CA 92123 USA Phone: +1 858 503 3300 Fax: +1 858 503 3301 Maxwell Technologies SA CH-1728 Rossens Switzerland Phone: +41 (0)26 411 85 00 Fax: +41 (0)26 411 85 05 Maxwell Technologies GmbH Brucker Strasse 21 D-82205 Gilching Germany Phone: +49 (0)8105 24 16 10 Fax: +49 (0)8105 24 16 19 Maxwell Technologies, Inc. Shanghai Representative Office #13E, CR Times Square 500 Zhangyang Road, Pudong Shanghai 200122, P.R. China Tel: +86 21 5836 8780 Fax: +86 21 5836 8790 www.maxwell.com User Manual – Low Duty Cycle Modules – Doc. no.: 1014204.3 Document no.: 1014204.2 ©2008-2010 Maxwell Technologies, Inc.® Page 8