Evolion®

January 2015
Evolion®
Installation and operating instructions
1. Safety
Make sure to study and follow all
instructions. Misusing the Evolion®
may cause it to overheat or ignite.
Do not short-circuit the power
terminals.
■■ Do not reverse connect the
power cables.
■■ Do not disassemble the unit.
■■ Do not subject the unit to
excessive vibrations or drop the
unit.
■■ Do not immerse the unit.
■■ Do not expose the unit to fire or
temperature higher than 100°C
(+212°F). It may cause the
cell safety vent to open which
renders the unit inoperable.
■■ Use only in Telecom power
systems with a maximum rated
output of 60 V.
■■ Refer to the Battery Information
Sheet (included) for emergency
response procedures.
■■
Figure 3 and Table 2. A hole in the
packaging allows you to access the
unit without removing it from the
box. Refer to Figure 2.
This will help to plan the next
refreshing charge.
Keep Evolion® in its original
packaging for continued storage or
for transportation.
Table 1 - Standard items in Evolion® kit
(771473-XX)
Part No
771492-XX
Qty
Evolion®
1
771285
Fuse, spare
1
780680
Power cable for positive
terminal (1 meter length)
1
772517
(Note 1)
Power cable for negative
terminal (1 meter length)
1
772518
(Note 1)
Communication cable
(1 meter length)
1
773455
RJ45 resistor cap
1
-XX: refers to the parameter file variant
Note 1: The cable Part N° varies according to heat
shrink color and cable color
2. Important recommendations
If smoke is emitted from a unit, stay
clear of the smoke and evacuate
the area until the smoke clears.
•Connect according to Section 6
•Make sure the set-point voltage on
the rectifier is 56.0 V
•Charge for a total time according
to the available charge current
(see Table 3)
Figure 2 - Accessing the unit
ON/OFF
button
SOC / SOH button
(State of Charge / State of Health)
Table 3 - Maintenance charge time
Figure 3 - Checking SOC (State of Charge)
Figure 1 - Evolion main front access
• For SOC, push and hold for 3 s or less
and observe the LED’s.
3. Unpacking and inspection
4. Storage
When shipped, the Evolion is
packaged in accordance with
UN3480 Class 9 Group 2.
Unpack and make sure all items
were received. Table 1 summarizes
the standard kit.
Store the battery in its original
packaging and in typical warehouse
conditions. The temperature should be
between 15°C to 30°C (59°F to 86°F).
®
®
If items were not received or if
anything is damaged contact your
local Saft representative.
If a long storage is planned (more
than 6 months), check and note the
SOC (State of Charge) according to
IMPORTANT: If the unit is left
ON, it may over discharge in less
than 3 weeks and render the unit
inoperable. It is mandatory to check
the SOC, every 6 months, while in
a long storage period. See Figure 3
and Table 2.
To conduct a maintenance charge:
RJ45 Jacks
LED’s
NOTE: The Evolion® unit will
periodically and automatically wake-up
to record its state and to initiate cell
balancing if necessary.
If the Evolion® is stored at a low SOC for
too long, it may eventually over discharge
and render the unit inoperable.
Refer to the Evolion® Technical
Manual for functional details.
See Figure 1 for operator interface
features.
In these conditions, the Evolion® can
be stored for up to 1 year from the
manufacturing date. Make sure the
unit is switched OFF during storage.
When OFF, the unit is in sleep
mode. In sleep mode, no voltage is
present on the terminals and the
internal electronic consumption is
very low.
Amps
per unit
Charging
time
Amps
per unit
Charging
time
3
15 h 20 min
12
3 h 50 min
4
11 h 30 min
15
3h
5
9 h 10 min
18
2 h 30 min
6
7 h 40 min
20
2 h 10 min
8
5 h 40 min
25
1 h 50 min
10
4 h 30 min
CL mode*
see Note 1
*Note 1: CL = current limit mode, use a charge
current less than IMR to avoid CL mode charge.
See Evolion® Technical Manual for more details.
Table 2 - SOC (State of Charge) LED legend
SOC LED
(LED steady for 5 s)
Minimum SOC
Maximum storage time
(at less than 30ºC)
≥75%
20 months
≥50%
13 months
≥25%
<10%
7 months
schedule
maintenance
charge
immediately
5. Transportation
Use the original packaging or
equivalent. Follow the necessary
transportation rules for Li-ion
batteries by consulting with your
company’s standard practice and
your local transportation regulations.
Secure the Evolion® to prevent violent
shock and other items from falling
onto it. The Evolion® must be OFF
during transportation.
6. Installation
+
bus
-
bus
+
Unit 1
+
-
+
+
Unit 2
-
+
Unit n
Unit 3
bus
-
bus
See Figure 4 for Evolion® features.
+
Power terminals M6
Heat sink
Grounding point M3
Handle
Emergency vent ports
Handle
Figure 4 - Evolion features (oriented
upright with front and back view)
®
Never block the heat sink.
Do not obstruct the emergency
vent ports.
■■ Install in environment with IP55
(NEMA3 outdoor) or higher
protection index.
■■ 95% maximum humidity
(non-condensing)
■■ Overall installation steps
(details follow):
1.Connect power
2.Connect communication (optional)
3.Startup
■■ Required tools
• 10 mm socket (for terminal)
• Multimeter (60 Vdc, ohms)
•Flat screwdriver (for cover removal)
• 7 mm socket (for fuse)
• Torque wrench (insulated)
■■
■■
Connect power
Always connect the Evolion® using
the provided cables in order to
balance the resistance in each
branch. See Figures 5 and 6 for power
connections schematics and options.
-
Unit 1
-
+
Unit 2
+
-
+
-
Unit n
Unit 3
OPTION 1 - For any
number of parallel
chained Evolions,
take off the power
bus connection
at the end of the
parallel connected
system. This is the
best way to balance
the resistance of
each.
NOTE: Can only be
used when the total
continuous bus
current is less than
or equal to 63 A.
OPTION 2 - For any
number of direct
connected Evolions,
using the same
length of cable
for each will make
sure to balance the
resistance.
Figure 6 - Parallel connecting Evolions
IMPORTANT: Never connect the
power terminals in series with other
Evolion® units. The Evolion® may be
damaged and rendered inoperable.
IMPORTANT: A reverse connection
on the power terminals may cause
an internal fuse fault. See Section
10 if replacing the fuse is necessary.
IMPORTANT: Parallel connecting can
be done as long as the total system
discharge current never exceeds
130 A (5 kW at 42 V) continuous.
In this case paralleling any number of
units is allowed.
Connect communication
Make sure to never parallel connect
Evolions that have more than 2 V
difference between the modules.
Equalizing the voltage by charging or
discharging modules separately may
be necessary. To check the open
circuit voltage when disconnected,
press the ON/OFF button for at
least 2 seconds and measure the
voltage at the terminals. Make sure
to turn the unit OFF by pressing
the ON/OFF button for at least 4
seconds.
See Table 4 for RJ45 jack pin
assignments.
Table 4 - RJ45 pin assignments
Pin 1
RS485+
Pin 2
RS485-
Pin 3
Ground (isolated from power terminals)
Pin 4
Wake up (ground referenced)
Pin 5
Reserved
Pin 6
Reserved
Pin 7
Dry contact alarm output
Pin 8
Dry contact alarm output
Both RJ45 jacks are interchangeable
and can be used to plug either the
communication cable (772518) or
the RJ45 resistor cap (773455).
The Evolion® limits its own current
with a built in charge regulated
circuit. However, starting up
the Evolion® to avoid the charge
regulated mode is important to avoid
a possible internal fuse fault.
To access the dry contact alarm
signal, use pins 7 and 8. Both minor
or major alarm signals are reported
and the default state of the pin is as
follows:
CLOSED = ALARM/power down
OPEN
= NO ALARM
Make sure to switch off the battery
breaker(s) before connecting Evolion®
power terminals to the power bus.
Use the communication cable
provided. See Figures 7 and 8.
Figure 5 - Connecting to terminals
The Evolion® power terminals can be
connected to systems with a positive
ground, a negative ground or a
floating ground system.
• Only use the terminal bolts, washers,
terminal protectors and cable lugs
provided.
• Terminal bolt torque = 6 N.m (53 in.lbs)
In order to prevent reverse connections,
make sure to measure and note the
polarity of the power bus cables.
Make sure to conduct an Evolion®
Installation and Commissioning
(I&C) prior to startup. Setting a
unique node ID (default = 1) for
each parallel connected Evolion® is
necessary in order to communicate
using the Saft Evolion® Toolbox
software during operation.
To shutdown the Evolion® when
connected to the application:
Install RJ45
resistor cap
on end
module
Saft p/n 773455
• Turn OFF the battery output
breaker.
• Push the Evolion’s ON/OFF button
for at least 4 s.
When the Evolion® is OFF, the LED’s
are inactive.
Application:
• Dry contact (pin7 & pin8)
• RS485 bus (pin1 & pin2)
• Wake up signal (pin3 & pin4)
Customer provided cable
The Evolion® will accept charge
current only when the temperature
is above - 30°C and below +75°C
(- 22°F and +167°F).
Table 7 - Maximum re-charge current
to manage thermal behavior of Evolion®
Cycling Frequency
Maximum allowed
Amps per Evolion®
(Note 1)
Figure 7 - Communication connecting
with one module
Application:
• Dry contact (pin7 & pin8)
• RS485 bus (pin1 & pin2)
• Wake up signal (pin3 & pin4)
Customer provided cable
Install RJ45
resistor cap
on end
module
Saft p/n 773455
Parallel connected
RJ45
Saft p/n 772518
Figure 8 - Communication connecting
with parallel modules
Startup
Table 5 - Rectifier output settings
#
Type
Setting
a.
Single level voltage
56.0 Vdc ± 0.5%
b.
Temperature
compensated
voltage control
Disabled or turned OFF.
c.
Maximum
re-charge current
See Table 7 (to
manage thermal
behavior)
d.
e.
f.
Ramp in voltage/
current (soft start)
When the AC powers
ON, output voltage/
current should ramp up
to single level voltage
over at least 1 minute.
Default rectifier
output voltage
When AC powers ON,
if the rectifier controller
is not available or
working, make sure to
set the default rectifier
output voltage to 46 V
maximum.
Low voltage
disconnect (if used)
45 Vdc ± 1%
To start up the Evolion® when
connected to the application:
• Switch ON the rectifier/breaker
output.
IMPORTANT: Do not use the ON/
OFF button to switch ON the Evolion®
when it is connected the power bus.
This may cause a fuse fault.
When the Evolion® is ON, the LED’s
are active indicating its operational
status (see Table 6).
ABNORMAL
NORMAL
Table 6 - Operating LED legend
slow blink
Floating
fast blink
Charging
steady
Discharging
steady
Low health
steady
Warning
steady
Alarm
Note: Refer to 10. Troubleshooting if ABNORMAL
LED is active.
7. Operation
The Evolion® is a “smart battery” and
will only allow safe operation. If a key
operating parameter is exceeded, the
Evolion® will automatically interrupt
or restrict its operation until the key
operating parameter is back within
acceptable limits. In this case the
alarm will be reset and operation will
continue normally. Some alarms are
only resettable by the BMST reset
button or by sending a BMST reset
command on the RS485/Modbus
communication bus.
The Evolion® is an RS485/Modbus
slave. Any user configured RS485/
Modbus master equipment can
communicate with the Evolion®. See
the Evolion® communication user
manual for more details
The Evolion is equipped with an
internal heater. It operates as
needed in charge and discharge
mode of operation.
®
During operation, the LED’s are
active and indicate the Evolion’s
status. See Table 6.
Charging
Make sure that output of the
rectifier is set as 56.0 V ± 0.5%.
It must be set higher than 49.0 V to
allow cell balancing during re-charge.
Temperature Compensated Voltage
(TCV) should be disabled. The Evolion®
is not harmed by TCV control but the
available capacity will be decreased by
10% for every 1 V below 56.0 V.
• When Evolion® is used in “floating
operation”, for which re-charge
time is not critical, the charge
current can be limited to 16 A per
Evolion® module.
• When Evolion® is used in “cycling
operation” the maximum current
will depend on the operating
temperature. Refer to Table 7.
• If the maximum allowed charged
current (IMR) is exceeded, the
Evolion® will automatically regulate
its own charge current by switching
to regulated charge. In that case,
the charge can last 24 h.
More than 4x per day
16
3x to 4x per day
21
2x to 3x per day
24
1x to 2x per day
Less than 1x per day
32
Less than IMR
*Note 1: The re-charge current can never be above
IMR to avoid charge regulated mode of operation.
Make sure to use the lowest value.
Discharging
The Evolion® will discharge above
- 30°C and below +75°C (- 22°F
and +167°F). The maximum allowed
discharge current is a function of
temperature.
IMPORTANT: If an Evolion® is
subjected to more than 130 A (5 kW
@ 42 V) of continuous discharge
current, a fuse fault will occur. See
Section 10 for fuse replacement.
The Evolion® will continuously
discharge until one of the following is
encountered.
•The rectifier output power returns,
or
•The battery reaches the minimum
set SOC (0% by default), or
•No discharge current is present
for a set time duration (default is
0), or
•The ON/OFF button is pushed for
at least 4 s, or
•The maximum allowed discharge
current is exceeded, or
•The low voltage disconnect is
reached (default is 42.0 V).
When the end of discharge is
encountered due to a low end
voltage, the Evolion® will eventually go
into sleep mode when the a low cell
voltage is reached.
IMPORTANT: After the end of
discharge to 42 V, the Evolion®
can remain in sleep mode for a
maximum of 14 days. If re-charge
does not begin within this time, the
Evolion® may be over discharged due
to its internal self-discharge. If over
discharged, it will not startup and
will indicate a major alarm that is
not resettable. The unit will need to
be replaced.
8. Maintenance
Table 8
The Evolion requires no maintenance,
but checking its state and taking
necessary action during periodic site
routines is recommended.
The SOC can be checked while in
operation. Refer to Figure 3 and
Table 2.
Check if the heat sink area is
obstructed or accumulated with
dirt and debris. As necessary,
un-obstruct or clean using a nonmetallic brush or a dry or damp
cloth. Do not use any cleaning
solvents or soaps. Do not immerse,
dunk, bathe or hose off the Evolion®.
Check the rectifier output. It should
be set at 56.0 V ± 0.5%.
Check the LED and verify that the
operating status is normal. Refer to
Table 6.
If an abnormal operation (see Table
6) is noticed, see Section 10.
®
9. Resetting the software
If an alarm that is not automatically
resettable or software trap is
encountered then push the reset
button using a pointed object. After
the unit can be restarted normally.
See Figure 9 below.
IMPORTANT: Only push the
reset button when the Evolion® is
disconnected from the application.
The Evolion® must be ON to reset.
steady
Emergency alarm
steady
Software trap
steady
Schedule a replacement of the Evolion® module.
Contact your local Saft representative for further details.
steady
The Evolion® can continue to operate normally.
Use the Evolion® Toolbox software to view the active alarms.
Troubleshoot the active alarms according to the Evolion® Technical Manual Appendix E.
Contact your local Saft representative for further assistance.
steady
The Evolion® is currently disconnected by its own internal switch.
Disconnect and remove the Evolion® from the application to prevent inadvertent waking
up and reconnecting with too much voltage difference (2 V maximum).
Use the Evolion® Toolbox software to view the active alarms.
Troubleshoot the active alarms according to the Evolion® Technical Manual Appendix E.
Put Evolion® back into service if alarms are successfully cleared. Make sure to
reconnect with less than 2 V difference between modules.
Contact your local Saft representative for further assistance.
Evolion® is OFF
on a live bus
The Evolion® is likely deep discharged.
Disconnect and remove the Evolion® from the application.
Contact your local Saft representative for further assistance.
If the Evolion® emits an unusual
smell, feels hot, changes shape or
appears abnormal in any other way,
conduct the following procedure:
1.Disconnect the Evolion® from power.
2.Shut-down the Evolion® by pushing
the ON/OFF button for at least 4 s.
3.Leave the Evolion® in place.
4.Call your local Saft representative
for further assistance.
To check and replace the fuse,
conduct the following procedure:
1.Shut-down the Evolion® by pushing
the ON/OFF button for at least 4 s.
2.Disconnect and un-install the
Evolion®.
3.Check and replace the fuse
according to Figure 10.
4.The Evolion® is now ready for
service.
11. Removal and recycling
Make sure to turn OFF the battery
breaker.
Push reset
button with a
pointed object
Figure 9 - Reset button
10. Troubleshooting
The Evolion® Toolbox software is the
best way to interrogate an Evolion®
during troubleshooting. Refer to the
Evolion® Technical Manual Appendix E
for troubleshooting alarm details.
If an abnormal operation status
is noticed, conduct the following
procedure (Table 8):
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
• Measure continuity. If good continuity,
the fuse is good. Re-install the cover.
1.Shut-down the Evolion® by pushing
the ON/OFF button for at least 4 s.
2.Disconnect the power terminals.
3.Disconnect alarm/communication
cables.
4.Remove the Evolion® and stage for
recycling.
5.Call your local Saft representative
for further assistance.
• If no continuity, remove and replace
the fuse using a 7 mm socket and
torque wrench with a torque of 3 N.m
(26.5 in.lbs). Re-install the cover.
Figure 10 - Replacing a fuse
Doc. Nº 21813-2-0115
Edition: January 2015
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
• Remove fuse cover by inserting, on either
side, a flat head screwdriver and twisting.
Produced in the UK by Arthur Associates Limited