80V 300Ah Lithium-ion Battery Pack Data Sheet

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1 80V 300Ah Lithium-ion Battery Pack Data Sheet 80 V, 300 amp-hour capacity, maintenance-free energy storage, IP65 design, fully integrated BMS, integrated fuse and safety relay protection, highly configurable I/O, event and lifetime data logging, isolated communications. Web: Phone: Fax: every last ion. Document Number: B

2 Copyright Copyright 2013 JTT Electronics Ltd. ( JTT ) All rights reserved. Disclaimer This data sheet is provided in association with, and is subject to, the terms and conditions contained in the Standard Terms and Conditions of Sale for JTT Electronics Ltd. for JTT Products. This includes the Limited Warranty and Remedy, Limitations of Liability, and Disclaimer and Release sections of those Standard Terms and Conditions. The information contained throughout this data sheet is thought to be up to date at the time of publication. JTT will endeavour to maintain this data sheet to reflect the most current information about the purchased products, but has no obligation to do so. JTT reserves the right to change the contents of this data sheet at any time without notice and assumes no liability for its accuracy. In the preparation of this data sheet, JTT has incorporated and/or compiled service information and maintenance procedures sourced from manufacturers and vendors of parts and components used in the manufacturing of this product. JTT has relied on those manufacturers and vendors for that information and has not verified it. The content of that third party information is not within JTT s control, and JTT cannot and will not take responsibility for that information. JTT shall not be liable for errors, omissions, missing data or any other matter, in respect of that information. It is not the intention of this data sheet to instruct personnel in using common sense, basic skills, and rules of, installation, service or repair. The customer is solely responsible for installing the products and for undertaking the installation in a safe environment, using appropriate equipment, by experienced personnel. Confidentiality The information contained in this document is the intellectual property of JTT Electronics Ltd. and is Commercially Confidential, subject to the confidentiality provisions of the Standard Terms and Conditions of Sale for JTT Electronics Ltd. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical, for any purpose, without the express written permission of JTT Electronics Ltd. i

3 Table of Contents 1. FEATURES DESCRIPTION APPLICATIONS OPERATIONS BLOCK DIAGRAM TYPICAL APPLICATION PRODUCT CHARACTERISTICS OPERATIONAL CURVES SIZE AND MOUNTING CONNECTORS AND PIN OUT BMS LINK SOFTWARE ii

4 1. FEATURES Efficient Maintenance-free energy storage Easy installation Discharge current of 300 A continuous, 600 A pulse Charge current of 150 A continuous, 300 A pulse BMS controlled cell balancing High operational reliability with outstanding lifetime BMS pack monitoring Event and lifetime data logging and reporting to external devices 65% the volume, 30% the weight of an equivalent lead acid battery pack (650 lb/295 kg) Safe Integrated BMS controlled safety relays Integrated current sensor Comprehensive S-Series BMS monitoring: o All cell voltages o All cell temperatures Internal fuse protection Protected BMS power input from 9-32 V Dual-layer hardware and software protection against: o overvoltage o undervoltage o over-temperature Fault management and diagnostics User configurable alarm thresholds Reliable Automotive grade components Rubber vibration absorbers at mounting points IP65 battery pack design Internally secured cells DN A 1

5 2. DESCRIPTION The JTT Electronics 80V 300Ah battery pack is a reliable, high-performance power source for HEV and EV systems. This standalone lithium-ion battery pack comes fully equipped with cells specifically chosen for optimum performance with any product. It requires no additional current sensor or external relays, though assigning control of additional relays to the pack's BMS is possible. Our integrated S-Series BMS controller monitors cell and pack conditions, and logs alarms and lifetime cell data in its internal memory. The BMS can communicate battery fault conditions, cell status information, and battery data via RS 232, CAN and GPIO communications. This information can be sent to a display, monitoring system, or an intelligent power supply depending on the application. The additional CAN bus is reserved for diagnostics communication with our BMS Link software for realtime battery monitoring, data logging, and troubleshooting. The battery pack balances cell charges to maximize runtime and extend its life. To accomplish this, energy is discharged from the cells with the highest charge in the pack. In extreme operating conditions, the battery will disconnect by opening the internal safety relays. This helps ensure safe operation and protects the battery pack. The battery pack also includes a 600A fuse to protect against overcurrent conditions. The 80 V fused output has its own 15 A fuse for auxiliary power supply, providing constant power to the system. The integrated BMS runs over 80 diagnostic checks 10 times per second, monitoring individual cell as well as battery pack conditions. Most of these diagnostics help ensure safe operation of the battery pack, while others monitor battery performance and lifetime. 3. APPLICATIONS Airport ground support equipment Industrial electric vehicles Industrial machinery 2

6 4. OPERATIONS INTERNAL SAFETY RELAY DISCONNECT In the event of unsafe conditions, the integrated BMS will automatically disconnect the battery pack from the system by opening the internal safety relays. INTEGRATED CURRENT MONITORING The battery pack is fully integrated with an automotive dual-range Hall effect sensor. This sensor allows the BMS to monitor both low and high currents in and out of the battery pack with high accuracy and fast response time. PASSIVE CELL BALANCING The integrated BMS intelligently balances cells by discharging energy at 250 ma (typical) from the cells with the highest charge levels. A well balanced battery pack will have higher capacity and longer runtime than an unbalanced one. Maintaining an equal charge between cells in a battery pack ensures that cells with slightly weaker performance are not degraded further by over-charging or overdischarging during operation. RELIABLE BMS POWER INPUT Reliable BMS power supply can be from 9-32 V. The onboard power input regulation has high voltage, low voltage, and reverse voltage protection; as well as high voltage transient, current injection, and load dump immunity. A simple 12 V or 24 V power supply cable can be connected from the 80 V fused output to provide regulated power to the BMS. CONFIGURABLE INPUTS/OUTPUTS The integrated BMS has 3 additional configurable I/O that can be configured as either analog outputs, digital inputs, or digital outputs in any combination. CONFIGURABLE COMMUNICATIONS Isolated CAN bus and isolated RS-232 can be configured for communications with external components such as displays, monitoring devices, DC chargers and other intelligent devices. ALARM MONITORING AND REPORTING Over 40 alarm conditions are evaluated at 10 times per second to ensure safe battery operation, and maximize battery pack performance and lifetime. Alarm thresholds can be customized for your application or operate with the default settings. Alarm status may be reported via CAN or RS-232. CELL VOLTAGE MONITORING Accurate voltage measurement of all cells allows for highly precise State of Charge (SOC) calculations. The integrated BMS measures cell voltages every 50 ms with a resolution of 1.5 mv. The high frequency of voltage measurements also ensures fastresponse to overvoltage and undervoltage events. CELL TEMPERATURE MONITORING Temperature sensing of every cell within the battery pack ensures that pack safety is always monitored and maintained. Temperature data is reported every 1 s with a resolution of 0.1 C. COMPREHENSIVE PC/LAPTOP DIAGNOSTICS Connecting a PC or laptop with the JTT BMS Link software tool (page 12) to the diagnostic RS-232 allows complete real-time monitoring of the battery pack and access to alarm history and cell lifetime data. 3

7 5. BLOCK DIAGRAM Figure 1. Block diagram of a JTT 80V 300Ah lithium-ion battery pack. 4

8 6. TYPICAL APPLICATION The JTT Electronics 80V 300Ah battery pack is generally used in medium voltage ( V) airport GSE (ground support equipment) and industrial EVs. Depending on the specific application the overall system can be configured differently. The following example shows the battery pack integrated into a system with a DC charger, a motor controller, and an 80 V to 12 V converter to provide power to the battery pack's BMS controller. Figure 2. Example system with a JTT Electronics 80V 300Ah battery pack connected to a charger, motor controller, and an 80 V to 12 V converter for BMS power supply. 5

9 7. PRODUCT CHARACTERISTICS For S-Series BMS communications, power and signal specifications, please see the S-Series BMS data sheet available on our website. PARAMETER MIN TYP MAX UNITS Battery Pack Specifications Voltage output V Capacity 300 Ah Energy 24 kwh Discharge current (continuous) A Charge current (continuous) A Volumetric energy density 100 Wh/L Gravimetric energy density 81 Wh/kg Physical Characteristics Width 29-1/4 (743) in (mm) Height (including lid case screws) 12-1/4 (312) in (mm) Length 47-3/8 (1203) in (mm) Weight 650 (295) lb (kg) Operating Conditions Discharge temperature range C Charge temperature range 0 45 C Storage temperature range 0 35 C Cycle life (80% DOD, 20 C) 2000 Cycles Current Sensor Specifications Measurement range (charge/discharge) A Measurement resolution 0.1 A Measurement period 50 ms Cell Voltage Monitoring Specifications Measurement range 0 5 V Measurement resolution 1.5 mv Measurement period 50 ms Cell Temperature Monitoring Specifications Measurement range C Measurement resolution 0.1 C Measurement period 1.0 s Cell Balancing Specifications Passive balancing current ma 1 10 second pulse current. 6

10 Voltage (V) 80V 300AH LITHIUM-ION BATTERY PACK 8. OPERATIONAL CURVES Operating Range A 150 A 100 A Capacity (Ah) Figure 3. Voltage response of the JTT 80 V 300 Ah battery pack during discharge. 7

11 9. SIZE AND MOUNTING All mounting holes are intended for 5/16" hex screws. Battery terminals are intended for M8 bolts. Allow an additional 3" (76 mm) at front of pack for connections. Figure 4. JTT 80V 300Ah battery pack with dimensions. 8

12 10. CONNECTORS AND PIN OUT Figure 5. Front view of JTT 80V 300Ah lithium-ion battery pack with headers. Connector Harness Plug P/N JTT Data JTT 80 V fused NOTE JTT Electronics battery packs ship with all required connectors. This information is provided in case you need to contact JTT Electronics for replacement parts. 9

13 Data Male Plug Bank 1 Pin Tag AWG Description 1 PWR +12 V V power 2 PWR +12 V V power 3 PWR GND V GND 4 PWR GND V GND 5 BMS Diag CAN H 20 BMS diagnostics CAN 6 BMS Diag CAN L 20 BMS diagnostics CAN 7 Main CAN H 20 Main CAN for charger, etc. 8 Main CAN L 20 Main CAN for charger, etc. 9 Volt Gauge Analog 22 Volt gauge analog output 10 SOC Gauge Analog 22 SOC gauge analog output 11 MTR CTRL 20 Motor controller enable control signal

14 80 V Fused Male Plug RS-232 Pin Tag AWG Description V V positive output 2 BAT_GND 14 Battery ground 11

15 11. BMS LINK SOFTWARE Monitor and diagnose battery pack problems from your PC or laptop in real-time. The most comprehensive, battery integrated monitoring, logging and control software. BMS Link software is available for all JTT products. Compatible with Windows XP and 7. Multi-page layout displays battery data in numerical and graphical form. Cell voltages, temperatures, SOC, SOH, cell DCRs, balancing status, alarm status, battery voltage, battery current, and more available in real-time. Service Mode available for additional data and troubleshooting. Controller identification by serial number and firmware version. Export and save data log files to Excel spreadsheets. Updates with all cell and battery pack information every 100 ms. Alarm status information. 12

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