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