Table of Contents. 350 V, 80 kw, 20 kwh, traction battery pack, specifications

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1 350 V, 80 kw, 20 kwh, traction battery pack, specifications Table of Contents 1 Description Block diagram Electrical Specifications...4 Pack...4 Charger...5 DC-DC converter Mechanical specifications Environmental specifications Thermal specifications Connectors Graphs Communications...13 Elithion Inc. 350 V, 80 kw, 20 kwh, traction pack, specifications, 04/19/12 sheet 1 of 15

2 1 Description Complete PHEV traction pack. 350 V, 20 kwh, 80 kw (164 kw peak) power battery pack 3 kw Charger, J1772 compatible 1.8 kw, 12 V, DC-DC converter Two sets of main HV outputs, each with interlock Three sets of low power, HV outputs, fused, with contactor Sturdy, isolated case; automotive grade connectors Safety disconnect, main fuse Liquid cooled Digital BMS Monitors every cell voltage and temperature; monitors current Controls included charger directly, load and regen through CAN bus Balances pack at 50 % SOC, dissipative balancing Evaluates SOH, SOC, DOD, pack resistance Detects loss of ground to pack isolation Reports periodically (CAN bus) BMS and pack status Current limits (CCL, DCL), Pack current and voltage Replies to PID requests for any additional available data Individual cell voltages, resistances, temperatures, location Min, avg and max cell voltages, resistances, temperatures Pack resistance, SOC, DOD, SOH, power, cumulative energy (in and out) Elithion Inc. 350 V, 80 kw, 20 kwh, traction pack, specifications, 04/19/12 sheet 2 of 15

3 2 Block diagram Main fuse Blower Disconnect Contactors Aux V DC-DC J1772 AC Charger Cells Cells Contactors, precharge HV DC out HV DC out HV1 HV2 CAN BMS Intlck Intlck The traction pack consists of Li-Ion cells Main fuse, safety disconnect A charger, J1772 AC inlet compatible A DC-DC converter, with 12 Vdc output A Battery Management System Two high voltage, high power outputs, with interlock inputs (to shut down pack if link is opened) One set of contactors, precharge Three high voltage, low power outputs, with one set of contactors Control connector with CAN bus Elithion Inc. 350 V, 80 kw, 20 kwh, traction pack, specifications, 04/19/12 sheet 3 of 15

4 3 Electrical Specifications Unless otherwise noted, 25 C, 0 A, 50 % SOC. Pack Battery Pack Voltage Capacity Item Conditions Min Nom Max Units 100 % SOC % SOC % SOC % SOC % SOC A, 0 C A, SOC, > 20 %, V -500 A, SOC, <90 %, 10 s A, SOC < 90 % A, 0 C kw charge, 32 Ω discharge 3 kw charge, 1.6 Ω discharge Ah kwh DC resistance 35 mω Maximum discharge current, total both outputs Maximum discharge power, total both outputs Maximum charge current, total both outputs and charger Maximum charge power, total both outputs and charger 0 C 1000 Continuous, SOC > 10 %, 60 Lpm cooling 237 A 10 s C 50 Continuous, SOC > 10 %, 60 Lpm cooling 80 kw 10s C 16 SOC < 90 %, 20 Lpm cooling -120 A SOC < 90 %, 10 s C -50 SOC < 90 %, 20 Lpm cooling -43 kw 10 s C -16 Precharge resist. 25 Ω Fusing Main, 500 V DC rated 500 A Ah kwh Elithion Inc. 350 V, 80 kw, 20 kwh, traction pack, specifications, 04/19/12 sheet 4 of 15

5 Aux outputs, 500 V DC rated, each output 20 Charger Item Conditions Min Nom Max Units Power 110 Vac, 0 to 90 % SOC 1 kw 220 Vac, 0 to 90 % SOC 3 Input voltage Vac DC-DC converter Item Conditions Min Nom Max Units Power Continuous, 20 to 100 % SOC kw Voltage 13.5 Vdc 4 Mechanical specifications Item Conditions Min Nom Max Units Volume Cell modules only 164 L Dimensions W x D x H Total, including charger 423 Cell modules only, per set, 2 sets total 42x75x26 cm Total, including charger 107 W x 120 D x 33 H Mass Cell modules only 217 kg Total, including charger Environmental specifications Item Conditions Min Nom Max Units Sealing IP53 Elithion Inc. 350 V, 80 kw, 20 kwh, traction pack, specifications, 04/19/12 sheet 5 of 15

6 6 Thermal specifications Ambient temperature Coolant temperature Item Conditions Min Nom Max Units Charge 0 45 C Discharge Storage, 3 months Storage Operational Heat capacity Cells only 0.64 J/gK Coolant Ethylene glycol Coolant flow 60 / 16 Lpm/ GPM Coolant pressure 25 C 0.88 / 129 N/mm^ 2 Pressure drop Max flow 0.1 / 15 /PSI Elithion Inc. 350 V, 80 kw, 20 kwh, traction pack, specifications, 04/19/12 sheet 6 of 15

7 Connectors Function Qty Family On pack Mate 350

(Smallparts) crimp: 16V24-O screw: 16D22-O Interlock

- housing: 19419-0008 sockets: 19420-0002 350 VDC,

circuits 7-way 1. + 2. - 3. + 4. n.a. 5. - 6. + 7.

(Powerwerks) housing: 206226-1 sockets: 66261-4 kit

7 7 Connectors Function Qty Family On pack Mate 350 VDC, main 2 pairs Leviton series 16, orange (Smallparts) crimp: 16V24-O screw: 16D22-O Interlock 2 Molex MX150L 2-way housing: sockets: VDC, Aux out 12 VDC out 1 Tyco CPC series 3 7 x power circuits 7-way n.a Anderson power SB120, gray (non-gendered) (Powerwerks) housing: sockets: kit with contacts: 6800G1 Elithion Inc. 350 V, 80 kw, 20 kwh, traction pack, specifications, 04/19/12 sheet 7 of 15

Signal 1 Molex MX150L 10-way (AVNET) 1. Gnd 2. CANL 3.

0194170024 Cooling 2 Steel 37 Flared Tube Fitting For

OD tube, flared 37 Sleve: 50695K222 McMaster Nut:

8 Signal 1 Molex MX150L 10-way (AVNET) 1. Gnd 2. CANL 3. CANH 4. J1772 in 5. J1772 out 6. Ser TX (2) 7. Ser RX (3) 8. Ser Gnd (5) V 10. Ignition housing: pins: or Cooling 2 Steel 37 Flared Tube Fitting For 1/2" Tube OD housing: sockets: /2" OD tube, flared 37 Sleve: 50695K222 McMaster Nut: 50695K228 McMaster Elithion Inc. 350 V, 80 kw, 20 kwh, traction pack, specifications, 04/19/12 sheet 8 of 15

9 8 Interface Elithion Inc. 350 V, 80 kw, 20 kwh, traction pack, specifications, 04/19/12 sheet 9 of 15

10 9 Graphs Pack voltage vs SOC at various currents Pack voltage [V] SOC [%] Resistance vs SOC Resistance [mω] Disch., 0 C Charge, 0 C Disch., 25 C Disch., 60 C Charge, 25 C Charge, 40 C SOC [%] Elithion Inc. 350 V, 80 kw, 20 kwh, traction pack, specifications, 04/19/12 sheet 10 of 15

11 550 Current vs SOC s disch. Current [A] Cont. disch. Cont. charge 10 s charge SOC [%] Power vs SOC Power [kw] s disch. Cont. disch. Cont. charge 10 s charge SOC [%] Elithion Inc. 350 V, 80 kw, 20 kwh, traction pack, specifications, 04/19/12 sheet 11 of 15

12 400 Performace vs current Pack voltage [V] Depletion duration [m] Efficiency [%] Output power [kw] Emitted heat power [kw] Current [A] Capacity loss vs number of cycles Capacity % 95.00% 90.00% 85.00% 80.00% 75.00% 70.00% 65.00% 60.00% 55.00% 50.00% Cycles Elithion Inc. 350 V, 80 kw, 20 kwh, traction pack, specifications, 04/19/12 sheet 12 of 15

13 10 Communications This traction pack places on the CAN bus the following messages. Notes: Progr. Period: 1 s Multi-byte values are big-endian: the MSB (Most Significant Byte) is in the lower numbered data byte (the left most byte in the following tables) The ID of the 1st message is programmable; the other messages use IDs following the 1st ID ID Default Data bytes Byte 0 Byte 1 Byte 2 Byte 3 Byte 4 Byte 5 Byte 6 Byte 7 ID h 8 "Elithion" (0) ID h 8 "2CN " + Rev level (0) ID h 7 State (1) Timer (2) Flags (3) Fault code (4) Level faults (5) Warnings (21) ID h 6 Pack voltage (6) Min Vtg (7) Min Vtg # (8) Max vtg (7) Max Vtg # (8) ID h 6 Current (9) Charge limit (10) Discharge limit (10) ID h 8 Batt. energy in (11) Batt. energy out (11) ID h 7 SOC (12) DOD (13) Capacity (14) 00h SOH (15) ID h 6 Temperat ure (16) - Min tmp (17) Min tmp # (8) Max tmp (17) Max tmp # (8) ID h 6 Pack resistance (19) Min res (20) Min res# (8) Max res (20) Max res# (8) Elithion Inc. 350 V, 80 kw, 20 kwh, traction pack, specifications, 04/19/12 sheet 13 of 15

14 Notes: 0. ASCII 1. State of system Bit 4: Relay fault Bit 3: Contactor K3 is on Bit 2: Contactor K2 is on Bit 1: Contactor K1 is on Bit 0: Fault state 2. Power up time [s]; after s, it overflows back to 0 3. Byte of flags: Bit 7: The Fan is on Bit 6: The LLIM is set Bit 5: The HLIM is set Bit 4: There is a CAN contactor request Bit 3: There is a hard wire contactor request Bit 2: The interlock is tripped Bit 1: There is power from the load Bit 0: There is power from the source 4. Fault code, stored: Driving off while plugged in Interlock is tripped Communication fault with a bank or cell Charge overcurrent Discharge overcurrent Over-temperature Under voltage Over voltage No battery voltage High voltage B- leak to chassis High voltage B+ leak to chassis Relay K1 is shorted Contactor K2 is shorted Contactor K3 is shorted Open K1 or K3, or shorted K2 Open K2 Excessive precharge time EEPROM stack overflow Loss of CAN from HVFE 5. Level fault flags: Bit 7: Over voltage Bit 6: Under voltage Elithion Inc. 350 V, 80 kw, 20 kwh, traction pack, specifications, 04/19/12 sheet 14 of 15

15 Bit 5: Over-temperature Bit 4: Discharge overcurrent Bit 3: Charge overcurrent Bit 2: Communication fault with a bank or cell Bit 1: Interlock is tripped Bit 0: Driving off while plugged in 6. Total voltage of pack [V], unsigned, 0 to 65 kv, as the sum of all cell voltages; {in rev 1.05 and above, if available, measured directly by the HVFE} 7. Voltages [100 mv] of least charged cell and most charged cell, 0 to 25.5 V {30 s average voltage in revs 1.04 and below} 8. ID of the cell that has the lowest / highest voltage / temperature / resistance. 1 to Pack current [A], signed, positive out of pack, -32kA to + 32kA, averaged over 1 s 10.Maximum current acceptable (charge) or available (discharge), unsigned, 0 to + 65kA [A] 11.Total energy in or out of battery, since manufacture. Unsigned, overflows back to 0 [kwh] 12.State Of Charge [%], unsigned, 0 to 100. When deeply discharged, its value does not go below 0 13.Depth Of Discharge [AH], unsigned, 0 to 65 kah. When deeply discharged, its value may exceed the actual capacity's value 14.Actual capacity of pack [AH], unsigned, 0 to 65 kah 15.State Of Health [%], unsigned, 0 to % = all OK {Starting from rev 0.97; in older revs only 6 bytes are sent in this message} 16.Average pack temperature [ C], signed, -127 C to +127 C 17.Temperatures [ C] of coldest and hottest sensors, signed, -127 C to +127 C Resistance [100 micro-ohm] of entire pack, unsigned, 0 to milliohm 20.Resistances [100 micro-ohm] of lowest and highest resistance cells, unsigned, 0 to 25.5 milliohm 21.Warning flags: {starting from rev 0.97; in rev < 0.97 the number of bytes was 6} Bit 7: - Bit 6: - Bit 5 (20h): hot temperature Bit 4 (10h): cold temperature Bit 3 (08h): discharge overcurrent Bit 2 (04h): charge overcurrent Bit 1 (02h): high voltage Bit 0 (01h): low voltage Note Specifications subject to change due to changes in requirements, technical limitations, or errors within them. Elithion will notify the client promptly should there be any change to these specifications. Elithion Inc. 350 V, 80 kw, 20 kwh, traction pack, specifications, 04/19/12 sheet 15 of 15

Cover. L5v2 Plug-In Conversion Module(PCM) Diagnostic Trouble Codes

Cover. L5v2 Plug-In Conversion Module(PCM) Diagnostic Trouble Codes Cover L5v2 Plug-In Conversion Module(PCM) Diagnostic Trouble Codes Copyright 2009 A123 Systems, Inc. All rights reserved DOCUMENT NOTICE: The information contained in this manual is the property of A123