75 Volt User Manual

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
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