Evolion®

April 2014
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.
Table 1 - Provided items in Evolion® kit
(771473-XX)
Part No
771492-XX
Qty
Evolion®
1
Fuse, spare
1
Note 1
Power cable for positive
terminal (800 mm length)
1
Note 1
Power cable for negative
terminal (800 mm length)
1
772518
Communication cable
1
773455
RJ45 resistor cap
1
771285
■■
Do not disassemble the unit.
■■
Do not subject the unit to
excessive vibrations or drop the
unit.
-XX:
refers to the parameter file variant
Note 1: Part N° varies according to heat shrink
color and cable color
■■
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.
If a long storage is planned, check
and note the SOC (State of Charge)
according to 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.
■■
Use only in Telecom power
systems.
■■
Refer to the Battery Information
Sheet (included) for emergency
response procedures.
If smoke is emitted from a unit,
stay clear of the smoke and
evacuate the area until the smoke
dissipates.
Figure 2 - Accessing the unit
SOC / SOH button
(State of Charge / State of Health)
Figure 1 - Evolion® main front access
3. Unpacking and inspection
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 provided items.
®
If items were not received or if
anything is damaged contact your
local Saft representative.
NOTE: The Evolion® unit will
periodically and automatically wake-up
to record its state and to initiate cell
balancing if necessary.
To conduct a maintenance charge:
•Connect according to Section 6
•Make sure the set-point voltage on
the rectifier is 56.0 V
RJ45 Jacks
ON/ OFF
button
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.
If the Evolion® is stored at a low SOC for
too long, it may eventually over discharge
and render the unit inoperable.
See Figure 1 for operator interface
features.
LED’s
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).
IMPORTANT: If the unit is left ON, it
may over discharge in a short time
and render the unit inoperable. It is
mandatory to check the SOC while in
storage every 6 months. See Figure 3
and Table 2.
2. Important recommendations
Refer to the Evolion® Technical
Manual for functional details.
4. Storage
•Charge for a total time according
to the available charge current
(see Table 3)
Figure 3 - Checking SOC (State of Charge)
• For SOC, push and hold for 3 s or
less and observe the LED’s.
This will help to plan the next
refreshing charge.
Keep Evolion® in its original
packaging for continued storage or
for transportation.
Table 3 - Charging time according to
the current
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
Table 2 - SOC (State of Charge) LED legend
CL mode* 11 h 30 min
*current limit mode
SOC LED
(steady for 5 s)
<25%
Minimum SOC
≥75%
≥50%
≥25%
charge as
soon as
possible
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.
Power terminals M6
Secure the Evolion® to prevent violent
shock and other items from falling
onto it. The battery must be OFF
during transportation.
Handle
Heat sink
Grounding point M3
Handle
6. Installation
See Figure 4 for Evolion® features.
Vent ports
Figure 4 - Evolion® features (oriented upright with front and back view)
Install in the upright position only.
■■
■■
To complete an Evolion®
installation:
1. Connect power
2. Connect alarms (optional)
3.Startup
+
bus
-
bus
Required tools
• 10 mm socket (for terminal)
• Voltmeter (0 to 60 V)
•Flat screwdriver (for cover removal)
• 7 mm socket (for fuse)
• Torque wrench
Connect power
The best practice when parallel
connecting Evolion® is 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
bus
-
bus
+
Unit 1
-
+
Unit 2
+
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.
-
Unit n
Figure 6 - Parallel connecting Evolions
Figure 5 - Connecting to terminals
• Only use the terminal bolts, washers,
terminal protectors and cable lugs
provided.
• Torque = 6 N.m (53 in.lbs)
IMPORTANT: Never connect the
power terminals in series with other
Evolion® units.
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.
To avoid high parasitic current
between parallel connected Evolion®
units, make sure that the open
circuit voltage is within 2 V of each
other. To check the open circuit
voltage when disconnected, press
the ON/OFF button for at least 2 s
and measure the voltage at the
terminals. Make sure to turn the unit
OFF by pressing the ON/OFF button
for at least 4 s.
External charge current limiters are
not necessary. The Evolion® limits its
own current.
The Evolion® can be connected with
live power without damage. However,
it is recommended to switch OFF any
battery breakers before connecting
to the power terminals.
It is recommended to parallel connect
Evolions with the same state of charge.
The Evolion® power terminals can be
connected to systems with a positive
ground, a negative ground or a
floating ground.
In order to prevent reverse connections,
make sure to measure and note the
polarity of the power bus cables.
IMPORTANT: A reverse connection
on the power terminals may blow
the internal fuse. See Section 10 if
replacing the fuse is necessary.
Make sure the heat sink on the front
face is not obstructed.
Connect alarms
See Table 4 for RJ45 jack pin
assignments.
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).
Table 5 - Operating LED legend
NORMAL
Pin 1
When the Evolion® is ON, the LED’s
are active indicating its operational
status (see Table 5).
ABNORMAL
Table 4 - RJ45 pin assignments
slow blink
Floating
fast blink
Charging
steady
Discharging
steady
Low health
steady
Warning
steady
Alarm
To shutdown the Evolion®:
The dry contact alarm signals are on
pins 7 and 8. For both minor or major
alarm, the default pin's state is:
CLOSED = ALARM/power down
OPEN
= NO ALARM
• Push the Evolion’s ON/OFF button
for at least 4 s.
Use the communication cable
provided to connect the dry contact
alarms. See Figures 7 and 8.
7. Operation
To connect several Evolions to
one network alarm terminal, the
RJ45 outputs of each unit can be
connected in parallel.
Install RJ45
resistor cap
on end
module
Saft p/n 773455
Application:
• Dry contact (pin7 & pin8)
• RS485 bus (pin1 & pin2)
• Wake up signal (pin3 & pin4)
Customer provided cable
Figure 7 - Communication connecting
with one module
Application:
• Dry contact (pin7 & pin8)
• RS485 bus (pin1 & pin2)
• Wake up signal (pin3 & pin4)
Customer provided cable
Parallel connected
RJ45
Saft p/n 772518
Install RJ45
resistor cap
on end
module
Saft p/n 773455
Figure 8 - Communication connecting
with parallel modules
NOTE: The communication cable
uses straight through wiring in order
to parallel connect the pins for each
Evolion®.
To start up the Evolion®:
• Switch ON the rectifier/breaker
output, or
• Push the Evolion's ON/OFF button
for at least 2 s (only when power
not connected to application), or
• Send a 12 V signal to pin 4 on the
RJ45 (ground is pin 3)
When the Evolion® is OFF, the LED’s
are inactive.
The Evolion® is a “smart battery” and
will allow only 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 not resettable.
The Evolion® can communicate with
other network devices using RS485
protocol and offers supervision
diagnostics with its BMS software.
See the Evolion® Technical Manual
for more details.
The Evolion® is equipped with an
internal heater. It operates as
needed when the rectifier power is
present or not.
During operation, the LED’s are
active and indicate the Evolion’s
status. See Table 5.
Charging
Make sure that output of the
rectifier is set as 56.0 V ± 1%.
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
runtime 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. Please refer to the
Evolion® Technical Manual for more
details. As a general rule, the
charge current should be limited
to 24 A per Evolion® module if
the operating temperature is
anticipated to be mostly higher
than 30°C. If the maximum allowed
charged current 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.
The Evolion® will accept charge
current only when the temperature
is above - 30°C and below +75°C
(- 22°F and +167°F).
CAREFUL: When the charge
regulation mode is active, the heat
sink will be hot to the touch.
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, the fuse may need to be
replaced.
The Evolion® will continuously
discharge until one of the following is
encountered.
•The rectifier output 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, the Evolion® will go into
sleep mode.
IMPORTANT: After the end of
discharge, 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
10. Troubleshooting
The Evolion® requires no
maintenance, but checking its
state and taking necessary action
during periodic site routines is
recommended.
The DiagWinBMS supervision
software is the best way to
interrogate an Evolion® during
troubleshooting. See Evolion®
DiagWinBMS & Bootloader
communication software I&O for
details. Refer to the "Evolion technical
manual" alarms and troubleshooting
section.
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.
Check the LED and verify that the
operating status is normal. Refer to
Table 5.
If an abnormal operation status 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.
steady
Emergency alarm
steady
Software trap
Push reset
button with a
pointed object
Figure 9 - Reset button
If an abnormal operation status is
noticed or the unit’s operation is
questionable, conduct the following
procedure:
1.Allow the unit to continue operating.
2.Take note of the operation status
on the LED (see Table 5).
3.Push the SOC/SOH button for less
than 3 s and note the SOC LED
status (see Table 2).
4.Measure and note the Evolion®
terminal voltage.
5.Call 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:
• Remove fuse cover by inserting,
on either side, a flat head
screwdriver and twisting.
• Measure continuity. If good
continuity, the fuse is good.
Re-install the cover.
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.
• 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
11. Removal and recycling
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.
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
Doc. Nº 21813-2-0414
Edition: April 2014
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