Due to the significant development in Lithium Technology over the last 5 years, the demand for replacing conventional Lead Acid (L/A) batteries with high performing Li-ION technology is rapidly increasing. This application note will summarize the key benefits of replacing Lead Acid batteries with Li-ION technology.
In addition, the application note describes how the Li-ION Battery should be constructed, where the Scalable Battery Protection Unit (s-BPU) is integrated and how the battery performance can be monitored and optimized.
Basically the same battery box can be used as the one used with L/A.
For some applications like forklifts, the battery would require increased weight to achieve the counterweight. Steel plates can be used.
The LiBAL s-BPU unit can be placed into all existing battery boxes, and is designed to stand upright to have easy access to PC communication port, cell monitoring wires, I/O cables and HV power line.
The s-BPU also contain a re-activation contact that will re- engage the BMS after an auto-off incident. The configura-tion of the auto-off function is done through the s-BMS PRO PC software.
The prismatic cells can be placed inside an existing L/A battery box. Typically there will be a significant empty space due to the higher energy density of Li-ION (LFP) compared to L/A. As a rule of thumb it should be expected that the same opera-tional range can be achieved with half the nominal capacity.
The LFP cell can be supplied in 100, 180 and 200 AH capacity and can be mounted in 8s for 24 V, 15s for 48V and 24s for 80V.
The cells can be mounted in parallel configuration up to 2000Ah.
In this 48V example, the complete battery pack is assembled. The s-BPU is installed and the cell monitoring wire to each of the 15 cells in series are mounted for cell voltage sensing and balancing.
In addition, 4 temperature sensors are positioned in the pack to observe the battery pack temperature.
Each cell is connected with busbars and the power line goes through the BPU to measure current going in and out of the battery and to secure the battery with a charge/discharge relay. The BPU can be connected to a vehicle controller, motorcontroller and charger through CAN.
The BPU can be connected to the BMS PRO PC software configuration tool through an RS232 connection. A USB to RS232 is supplied with the PRO PC software configuration tool.
Configuration of the s-BPU though PRO PC software is facilitated by Lithium Balance application Engineers, who will provide up to 5 hours of free support along with the software license. The software license is a one off purchase.
Optional: Connect display/SOC indicator to s-BPU.
Optional: Connect to BatAnalytics datalogger and on-line battery data server.
The following considerations should be taken, where Lithium Balance application engineers can support: