UDS-KPM-094-01B-2
1
Industrial Lithium Ion Battery Module
LIM50EN-12S2-F2
Thank you very much for purchasing our products.
■ In order to use the products properly and safely,
read this “Instructional Manual” before installing the batteries.
■ Read the “Safety Precautions” (pages 3-5) before using the product.
■ Retain this “Instruction Manual” for future reference and
keep it in an easily accessible place.
GS Yuasa International Ltd.
Industrial Batteries and Power Sources Business Unit
Power Supply System Production Division
Instruction Manual
UDS-KPM-094-01B-2
2
Table of Contents
1. Prior to Use
1.1 Safety Precautions 3
1.2 System Summary 6
1.3 Name and Function of Module Components 7
2. Installation and Operation
2.1 Unpacking and Inspection 9
2.2 Installation and Wiring 10
2.3 Connector Input/Output Summary Table 13
2.4 Charging and Discharging 14
2.5 Storage 15
2.6 Maintenance and Inspection 17
3. Additional Information
3.1 Troubleshooting 18
3.2 Battery Specifications 19
3.3 Lithium-ion Battery Disposal & Recycling 20
UDS-KPM-094-01B-2
3
1. Prior to Use
1.1 Safety Precautions
This section explains the precautions that must be followed to avoid harm to
persons or property damage.
■ Items which can lead to an accident resulting in injury, death or property damage if
mishandled are classified in three levels - DANGER, WARNING and CAUTION -
depending on the severity.
Note 1 Serious injury is an injury such as loss of eyesight, wound, burn, electric shock, and
bone fractures that may require hospitalization and long-term health care.
Note 2 Minor or Moderate Injury is an injury, such as burn and electric shock, which is not
applicable to the definition of the serious injury.
Note 3 Property damage is damage caused to the building where this product is located, or any
device, equipment or system connected to this product.
■ In this instruction manual, the following symbols are used along with the messages to
express the precautions.
UDS-KPM-094-01B-2
4
■ To Protect from fire
If handled incorrectly a lithium ion battery can cause heat, fire, and explosion. Please follow the safety
instruction below. If any action that applies to any of the following prohibited items should be taken, stop
using the battery module.
Caution: Flammable
Do not throw in fire and avoid overheating.
Disassembly Prohibited
Do not disassemble.
※Do not alter the built-in battery monitor board or software.
Water Prohibited
Do not expose to moisture and do not immerse in water.
※When installing outdoor, place module in enclosure which meets water
proofing specification.
Prohibited: General
・ Do not short the battery’s positive terminal (+) and negative terminal (-).
・ Do not mechanically shock the battery.
・ Do not store under high temperature or at a high state of charge.
・ Do not charge by the methods other than specified.
・ Do not use for the devices other than specified.
General Instruction
・ Always use the battery management system supplied by GS Yuasa
when operating the battery.
・ When an error occurs, the batteries are protected by the battery
management system.
WARNING
UDS-KPM-094-01B-2
5
■ To protect against battery and device damage
To use safely, please follow the rules on the following prohibited and instruction items.
In case any action that applies to any of the following prohibited items should be taken, contact us for
judging the continuous use of the used module.
Prohibited: General
・ Do not use in the environments other than mentioned in the
specifications document.
・ Do not mix with different model batteries or the batteries made by
another company.
・ Do not use an over discharged battery.
* Charging the battery once over discharged can cause the battery to heat up,
ignite and explode.
・ Do not carry (the battery) by holding the battery terminals.
* Damage to the battery may result.
・ Do not mix new batteries with old batteries.
* Battery performance may be degraded.
General Instruction
・ Handle with care when transporting or carrying.
* The batteries are heavy. Do not stack the batteries in or out of their shipping
boxes.
・ Do not leave the battery monitor board operating.
* The battery can be over-discharged by the current consumption of the monitor
board.
・ Be sure to ground the module housing.
In securing the module housing by using a M8 bolt, ensure grounding by
inserting a toothed lock washer (see Sec. 2.2.2).
・ Use the specified torque to tighten the battery terminals
(see Sec. 2.2.3).
・ When storing the batteries, follow the required conditions and implement
the regular inspections.
* Storing in the conditions other than specified can lower the battery
performance.
・ When charging/discharging the batteries, always operate the batteries
within the following parameters:
Max. Cell Voltage: 4.10 V
Min. Cell Voltage: 2.75 V
Max. Charge Current: 125 A
Max. Discharge Current: 300 A (60 sec)
Continuous power current: 35 A (effective value)
Ambient temperature: -10 to 45 ℃ (recommended: 25 ± 5 ℃)
Storage temperature: - 25 to 60 ℃ (recommended: 0 to 35 ℃)
SOC range: 0 to 100 %
CAUTION
UDS-KPM-094-01B-2
6
1.2 System Summary
Figure 1．Lithium Ion Battery System Diagram
Figure 1 shows the block diagram of a typical Lithium Ion Battery System. This system
consists of multiple battery modules connected in series and the battery management
system.
This product uses a host battery management system. All the modules act as terminal modules
(children). The host management system monitors for defects, external output, and external
communication.
Here describes the handling of the battery modules:
* Glossary
Name
Description
Battery Module
A lithium-ion secondary battery module. Consisted of multiple cells, the
battery monitor board monitors the module temperature and balances
the battery voltage.
Lithium-ion
Battery Monitor
(LIBM II)
A device that receives battery module information sent by battery monitor
board. Based on this information, this calculates SOC (state of charge),
judges defects and performs communication and contact output.
The battery information can be checked on the touch panel or PC
monitor.
SOC [%]
State Of Charge = The state of charge.
The full charge state being 100% and the complete discharge state being
0%, SOC indicates the actual operable range of the battery.
Battery Module
Main circuit
MCCB
RS485 Comm., CAN Comm. Contact Output
Module Communication
Lithium Ion Battery Monitor
PC Monitor
Touch Panel Display
SOC
calculation
error detection
Monitor
Board
Monitor
Board
Monitor
Board
Customer
Equipment
(such as
converter)
UDS-KPM-094-01B-2
7
1.3 Name and Function of Module Components
Figure 2．Appearance of Module Front Side
Figure 3．Appearance of Module Rear Side
(2) Negative Battery Terminal
(with Terminal Protection
Cover)
(4) Battery Monitor Board (Built-In)
(1) Positive Battery Terminal
(with Terminal Protection Cover)
(5) Communication
Connector
CN2: Communication
Transmitter
CN1: Communication
Receiver
(6) Fixing Parts at Front (2 parts)
(3) Terminal
Protection Cover
(7) Fixing Parts at Rear (2 parts)
(9) Grip Part at Rear
(8) Handle
⑨
UDS-KPM-094-01B-2
8
(1) Positive Battery Terminal
The terminal for connecting the external cable. When attached, ensure the distribution cable
is in full contact with the battery terminal and is secured with the enclosed M8 (opposite
side: 12). The thickness of the connectable cable should be 60 mm
2
or less. In lieu of a
cable, a copper bar may be used to connect to the battery terminal. The copper bar
maximum dimensions are 20 to 25 mm Width × 2 to 4 mm Thickness.
(2) Negative Battery Terminal
The negative battery terminal uses the same design as that of the positive battery terminal.
The positive terminal is provided at the right, and the negative terminal is at the left.
(3) Terminal Protection Cover
The cover protecting the positive and negative battery terminals. Note that the exposed
terminals are danger. After wiring, make sure to install terminal protection covers.
(4) Battery Monitor Board (Built-In)
An electrical terminal for monitoring the battery voltage or module temperature as well as
equalizing the battery voltage.
(5) Communication Connector
A communication connector with LIBM.
CN1: Communication Receiver, CN2: Communication Transmitter
(6) Fixing Parts at Front
Use bolts (M8) at the two cutout parts to fix the battery module.
(7) Fixing Parts at Rear
Use bolts (M8) at the two cutout parts to fix the battery module.
(8) Handle
A handle to take out the battery module from the battery rack.
(9) Grip Part at Rear
A grip part at the rear side of the module. When carrying the battery module, be sure to hold
this part.
UDS-KPM-094-01B-2
9
2. Installation and Operation
2.1 Unpacking and Inspection
During battery module unpacking and handling, follow the precautions below.
● Handle with care when unpacking and avoid any shock impacts to the battery module.
● If there is any abnormality, such as odor from the battery module, battery leakage or
external damage, stop using the battery module and contact us (GS Yuasa International
Ltd.).
● The battery module is heavy. Be careful when carrying. When handling, do not drop, tip
over, or stack the battery modules.
● For carrying the battery module, be sure to tightly hold the handles on the front side and
the grip part on the rear side.
Figure 4. Carrying the Module
● Do not carry the battery module by holding the terminal(s).
● When shipping the battery module, be sure to contact us (GS Yuasa International Ltd.).
Note: Conforming to the UN Recommendations on the Transportation of Dangerous Goods
is required for transporting lithium ion batteries.
● Do not place any objects on the battery module. Otherwise it may cause short-circuit.
UDS-KPM-094-01B-2
10
2.2 Installation and Wiring
2.2.1 Installation Environment Check
Prior to installation of battery modules, ensure that the installation environment meets the
following requirements:
● Ambient Temperature
During Charge: -10 to 45 ℃
During Discharge:-10 to 45 ℃
(Ambient Temperature is the temperature 1 cm away from the battery module.)
● Humidity：0 to 90 % (no condensation)
● Well-ventilated area
● No heating element or nearby spark potential
● No direct sun
● No exposure to water or seawater
● Minimal dust
2.2.2 Battery Module Installation
Check the following items prior to setting up and installing the battery module.
● Mount securely the battery module (fixing parts at front and rear, see p.7) to avoid any
direct force to the battery terminals.
● Mount securely the battery module so that it is not shifted or influenced by vibration of the
mounted devices.
● Be sure to ground the module housing.
In securing the module housing, be sure to perform grounding by using a toothed lock
washer, and secure it by using a M8 bolt. Note that a toothed lock washer and a M8 bolt
are not included in the accessory. Prepare them at a customer’s side.
Figure 5. Securing Example of Battery Module
Secure by a M8 bolt (Not supplied).
CAUTION
Securely install the battery module so that
it is not shifted due to vibration.
UDS-KPM-094-01B-2
11
2.2.3 Wiring
Incorrect or incomplete battery wiring may cause the battery to heat up, ignite and/or explode.
Wire correctly by following the precautions and procedures below.
Main Circuit Wiring Precautions
● When wiring, wear safety glasses, rubber gloves, and rubber sole shoes.
● To prevent accidental short-circuits to the battery, all metal tools and jigs shall be
insulated. Also, remove all metallic items (watch, metal ruler, etc.) before beginning
work.
● Only one person should install a wiring cable to each battery terminal; do not wire
multiple locations with two or more people at a time (Battery terminal tightening may be
forgotten.)
● Do not apply a torque larger than the specified value (10 Nm). Otherwise, the battery may
be damaged.
● Do not short-circuit the (+) terminal and the (─) terminal, the (+) terminal and the battery
rack, or the (─) terminal and the battery rack. Wiring and cable insulation should be
selected so that normal degradation of the insulation will not cause short-circuits as
described above.
● Limit the thickness of the cable connected to the battery terminal to 60 mm
2
or less and
use a wire gauge appropriate to the conduction current. The crimp terminal size is M8. In
lieu of a cable, a copper bar may be used to connect to the battery terminal. The copper
bar maximum dimensions are 20 to 25 mm Width × 2 to 4 mm Thickness.
● For tightening the nuts of the battery module terminals, use the enclosed nut.
Main Circuit Wiring Procedure
Step 1: Verify the following battery module voltages prior to connection.
[A] When connecting two (2) or more battery modules in series:
Do not mix* old and new batteries together.
The voltage of the battery modules in series must be the same.
(The difference of the module voltage is within 0.7 V.)
* Do not mix new batteries with old batteries or do not connect batteries with different type of
voltage in series. Battery performance may be degraded.
[B] When connecting two (2) or more battery modules in parallel:
The voltage of the battery modules in parallel must be the same.
(The difference in the module voltage should be within 0.7 V.)
WARNING: Connecting modules with different voltages in parallel will cause a cross current
between modules and is extremely dangerous.
* Contact us for series/parallel connection.
UDS-KPM-094-01B-2
12
Step 2: During module wiring, remove only one terminal protection cover from the battery at a
time. To protect against short-circuits, always leave the terminal protection cover on for
the terminal not being wired. Remove the terminal protection cover by pinching both
sides (or pressing one side) of the opening sections, and by bending the terminal
protection cover.
(b) Opening Section Facing Left (c)Opening Section Facing Downward
Figure 6. Removing the Terminal Protection Cover
For tightening the enclosed nut M8 (opposite side 12) of the battery module terminals, use
a torque wrench and securely tighten to the specified value. Do not apply a torque larger
than the specified value. Otherwise, the battery may be damaged.
When tightening is difficult, stop tightening and check if the nut is cross-threaded, check
for the presence of foreign material on the threads. Also check if the nut thread pitch is
correct. Then remove the nut and tighten again.
Tightening Torque
10 ± 1 Nm
Step 3: Recheck that the battery terminal wiring is correct and matches the applicable drawing.
Step 4: Check that the main circuit wire or the communication wire between the battery modules
has not been damaged. Perform also the voltage leak check.
Step 5: After wiring and the voltage leak check, recheck that the nuts of the battery terminals are
tightened at the appropriate torque (Double-check).
CAUTION: When any storage battery error occurs, be sure to separate the main battery circuit for
protection. Insufficiently tightening of the battery terminals or continuing to use the
battery with defects may cause the battery to heat up and burn.
Press the Side
Press the Side
UDS-KPM-094-01B-2
13
Wiring Procedure of Communication Line
The system using LIBM
・Connect CN1 (Receive) with CN2 (Transmit) of the modules and connect CN1 and
CN2 of the module with CN4 (Receive) and CN3 (Transmit) of LIBM to wire the
communication line in a loop.
・Ensure that the LIBM external output signaling is used to control the system.
・For operation of the LIBM, refer to the LIBM instruction manual.
2.3 Connector Input/Output Summary Table
Table 1 shows the connector input/output and the pin assignments of the battery module. CN1
is a receiver of module communication and CN2 is a transmitter of module communication.
Table 1. Connector Input/Output and Pin Assignments
Name
Connector
Model Name
Application
Pin Number
Remark
CN1
D1200D-6P
(1-1903131-3)
* Data Reception
(Current Loop Comm.)
* External Startup
Signal Voltage Input
(4.5 to 5.5 V DC）
* Communication.
receive (A1, B1)
* External Startup
Signal receive
(A3, B3)
A1pin: Reception (+)
B1pin: Reception (-)
A2pin: Unused
B2pin: Unused
A3pin: Ext. startup sig. vol. (+)
B3pin: Ext. startup sig. vol. (-)
CN2
D1200D-4P
（1-1903131-2）
* Data Transmission
(Current Loop Comm.)
* External Startup
Signal Voltage Output
(4.5 to 5.5 V DC）
* Communication
transmission
(A1, B1)
*External Startup
Signal transmit
(A2, B2)
A1pin: Transmission (+)
B1pin: Transmission (-)
A2pin: Ext. startup sig. vol. (+)
B2pin: Ext. startup sig. vol. (-)
UDS-KPM-094-01B-2
14
2.4 Charging and Discharging
Charging or discharging using an incorrect method could make the battery module unusable
and may also cause the battery module to heat up, ignite or explode. For safe use, follow the
precautions below for charging or discharging.
Precautions prior to Charging/Discharging
* Make sure that the environment meets the required conditions mentioned in section 2.2.1.
* Select an appropriate charger, and read the instruction manual and specifications manual
before use.
Precautions during Charging/Discharging
(1) Charge/Discharge Control
Control the battery charge/discharge to the requirements below.
* Max. Cell Voltage: 4.10 V * Max. Charge Current: 125 A
* Min. Cell Voltage: 2.75 V * Max. Discharge Current: 300 A (60 sec.)
* Ambient Temperature for Battery:-10 ℃ to 45 ℃
* Continuous Current: 35 A (Effective Value)
* SOC Range: 0 to 100 %
(2) Charge Current and Module Temperature
Be sure to perform charging within the range specified below:
Figure 7. Reduction Curve of Charge Current by Module Temperature
Module temperature [ºC]
Charge current [A]
UDS-KPM-094-01B-2
15
(3) Monitoring Battery during Charge/Discharge
When charging or discharging, always monitor the batteries with the Lithium Ion Battery
Management System (LIBM II). Failure to monitor the batteries could make the batteries
unusable and could cause (the batteries) to heat up, ignite and/or explode.
UDS-KPM-094-01B-2
16
2.5 Storage
Storing the battery module in an incorrect manner could lower its performance considerably.
Follow the precautions and instructions below for proper battery storage.
Battery Module Storage Method
(1) Storage Conditions
When storing the battery module store under the following conditions:
・ Recommended Temperature 0 ℃ to + 35 ℃ (no condensation):
Storing in an environment other than this specification could degrade the battery
module performance.
・ Allowable Temperature –25 ℃ to +60 ℃ (no condensation):
Do not store in an environment other than this specification.
(2) Storage Precautions
• Disconnect the battery module from the charger and the load.
• Turn off the battery monitor board (including the control power stop of this Lithium Ion
Battery System (LIBM II)).
CAUTION: The power source for the battery monitor board is the battery itself. If the battery
module remains connected to an operating battery monitor board during storage,
the battery module will become over discharged and may become unusable.
(3) Open Circuit Voltage Measurement and Auxiliary Charge
Measure and record the battery module’s Open Circuit Voltage (OCV) regularly during
storage. Measure the voltage by inserting the measure pin through the measurement
hole on the top side of the module.
Temperature condition
Measurement Interval
Controlled at 25 ℃ or less
Once a year or more
Without temperature control
Once a quarter or more
CAUTION: The top side of the product is covered with the plate.
Pay ample attention to protect the metal part of the measure from any contact with
the plate. Otherwise it may cause short-circuit to the battery.
UDS-KPM-094-01B-2
17
Hole for Voltage
Measurement
Figure 9. Placement of Batteries (Cells) in Module
The battery voltage will decrease gradually during storage. Perform auxiliary charging as
necessary to maintain the module voltage at 2.75 V.
WARNING: If the battery voltage lowers to 2.75 V or less, the battery is being
over-discharged. Charging an over-discharged battery could cause the module to
heat-up, ignite and/or explode. Stop using the battery module and contact us once
it is over discharged.
Auxiliary Charging Method of Battery Module
(1) For auxiliary charging, use the charger with “constant current/constant voltage (CCCV)”
function and “Over Voltage Protection (OVP)” function.
(2) Set the Over Voltage Protection (OVP) to 49.2 V (4.10 V / battery).
(3) Set the constant current (current drooping) to 50 A or less.
(4) Set the output voltage to 45.6 V (3.80 V / battery).
(5) When the value still remains within the constant
current value (CC) even after charged for the time
shown in the table below, stop charging and contact us.
* Put a higher priority on the specified auxiliary charging
method for the system at the delivery destination, if any.
Figure 8. Battery Voltage Measurement Method
Charging
current
Approx.
charging time
50 A
1 hour
25 A
2 hours
10 A
5 hours
cell1
cell2
cell3
cell6
cell5
cell4
cell7
cell12
cell8
cell9
cell10
cell11
UDS-KPM-094-01B-2
18
2.6 Maintenance and Inspection
Perform the regular inspections of the battery modules following the precautions and
instructions below.
Precautions prior to Battery Module Maintenance and Inspection
・ For maintenance and inspection, wear safety glasses, rubber gloves, and rubber sole
shoes.
・ For inspection, use insulated tools (with the withstand voltage higher than the battery
system’s max. voltage).
・ Inspection must be performed by a person who completely understands the handling
method and the hazards associated with lithium-ion cells.
・ If removal of battery module is necessary for inspection, avoid doing so when it is in the
fully charged state. We recommend discharging the module to its lowest level of charge.
Battery Module Maintenance and Inspection Methods
Perform the regular inspections shown in the table below.
Annual Inspection
Inspection Item
Point for Inspection/Test
(1)
Battery Module Terminal
Nut
Check for loosening of nut
(2)
Battery Module
Appearance
Check for deformation or damages
Check for leakage
(3)
Cleaning of Battery Rack
Inside
Cleaning depending on the condition
(4)
Terminals and Wiring
inside of Battery Rack
Check for damages or discoloration of electric
cables
Connector conditions
UDS-KPM-094-01B-2
19
3. Additional Information
3.1 Troubleshooting
When an error item is alarmed from the Lithium Ion Battery Management System (LIBM
II), take appropriate corrective actions by following the instructions shown in the table below.
Item
Occurrence
Condition
Check Item and Process
1
Cell Voltage
Up Error
When the maximum
cell voltage exceeds
the set value
(1) Check that the charge is stopped. If the charge continues,
take an action such as stopping the charger or turning off
the breaker to stop the charge.
(2) Contact us.
2
Cell Voltage
Down Error
When the minimum
cell voltage
becomes less than
the set value
(1) Check that the discharge is stopped. If the discharge
continues, take an action such as turning off the breaker to
stop the discharge.
(2) Contact us.
3
Battery Temp
Up Error
When any module
temperature
exceeds the set
value
(1) Check the battery module temperature. If the temperature
exceeds the setting value, check that the charge/discharge
is stopped. If the charge/discharge continues, take an action
to stop the charge/discharge.
(2) Check the ambient temperature. If the ambient temperature
exceeds the battery’s operating temperature range, lower
the ambient temperature.
(3) Check the module temperature once the ambient
temperature becomes within the battery’s operating range. If
the module temperature remains high, contact us.
4
Battery Temp
Down Error
When any module
temperature
becomes below the
setting value
(1) Check the battery module temperature. If the temperature
lowers the setting value, check that the charge/discharge is
stopped. If the charge/discharge continues, take an action to
stop the charge/discharge.
(2) Check the ambient temperature. If the ambient temperature
lowers the battery’s operating temperature range, increase
the ambient temperature.
(3) Check the module temperature once the ambient
temperature becomes within the battery’s operating range. If
the module temperature remains low, contact us.
5
Module
Communication
Error
When no reply from
the battery monitor
board after 30 sec.
or longer
(1) Check if the communication line between the battery module
and the Lithium Ion Battery Monitor (LIBM) and the
communication line between the modules are not
disconnected.
(2) Check that the charge/discharge is stopped. If the
charge/discharge continues, take an action such as turning
off the breaker to stop the charge/discharge.
(3) If there is no problem, contact us.
6
Battery
Management
System Error
(LIBM Error)
If there is an error to
the setting value
memorized in
nonvolatile memory
(1) Check that the charge/discharge is stopped. If the
charge/discharge continues, take an action such as turning
off the breaker to stop the charge/discharge.
(2) Contact us.
UDS-KPM-094-01B-2
20
3.2 Battery Specifications
3.2.1 Battery Module Appearance
3.2.2 Battery Module Specifications
Item
Description
Model
LIM50EN-12S2-F2
External Dimensions
219 (W) ×617+(1.7)
※
1
(D) × 128 (H) [mm]
Weight
27 kg or less
Nominal Voltage
44.4 V
Maximum Operating
Voltage Range
33.0 to 49.2V (2.75 to 4.1 V / battery x 12 cells)
Capacity
47.5 Ah
Electric Current
Max. Charge: 125 A
Max Discharge: 300 A (60 sec.)
Continuous Charge/Discharge: 35 A (Effective Value)
Cooling Method
Self-Cooling
※1
Values inside parentheses are the dimension for the protruding handle.
3.2.3 Cell Outline
Item
Description
Positive Electrode
Lithium – Coated with transition metal compound oxide, and dried on
the metallic foil.
Negative Electrode
Coated with carbon material, and dried on the metallic foil.
Separator
Microporous polyolefin film
Electrolyte Solution
Organic electrolyte solution
Terminals (+) or (-)
Nickel-plate copper
Case, Cover Plate
Stainless steel
Valve
To safeguard against excessive pressure build-up in the cell, there is a
stainless steel release valve.
Top Side
Front Side
Lateral Side
Rear Side
Page is loading ...
-
1
-
2
-
3
-
4
-
5
-
6
-
7
-
8
-
9
-
10
-
11
-
12
-
13
-
14
-
15
-
16
-
17
-
18
-
19
-
20
-
21
Ask a question and I''ll find the answer in the document
Finding information in a document is now easier with AI
Other documents
-
Makita UH200DZ Datasheet
-
Broan H4HK, 3, 5 Kw 240V,1-Phase Electric Heater Kit - B Series Product information
-
-
-
Greenheck 472786 Utility Distribution System Operating instructions
-
TOA BP-920A Rechargeable Lithium-Ion Battery User manual
-
Tacens MF12 Datasheet
-
Intermec CN2 Operating instructions
-
-
Volvo MD Engine Workshop Manual