Battery Management Manual

Revision D01

FPRA Flexi Power Rectifier

Battery Management Manual
Revision D01

Page 1 of 9

1/23/2009

Battery Management Manual

Revision D01

History:
Date 23.01.09 Version D01 Author Daniel Kreuzer Change Notes Creation of document

Authors:
Daniel Kreuzer daniel.kreuzer@emerson.com

Abbreviations:
tbd GUI DDU PDA MAC IP LCD CU PID VPN to be done Web-based User Interface DC Distribution Unit Power Distribution Assembly Media Access Control Internet Protocol Liquid Crystal Display Control Product Information Data Virtual Private Network

Related Documents:
User Manual FPRA D02 by Daniel Kreuzer: how to use for the Web-based User Interface and for the LCD Front-Panel Display of the FPRA system

Page 2 of 9

1/23/2009

Battery Management Manual

Revision D01

Content
1 2 3 Overview .................................................................................................................................. 4 Battery Charge/Discharge/Recharge Concept .................................................................. 5 The Example System .............................................................................................................. 7 3.1 3.2 3.3 3.4 3.5 Start-up ............................................................................................................................... 7 Idle/Charge Off.................................................................................................................. 7 Discharge/Boost Discharge ............................................................................................. 8 Charge/Boost Charge........................................................................................................ 8 Battery Test ........................................................................................................................ 9

Page 3 of 9

1/23/2009

Battery Management Manual

Revision D01

1 Overview
This document is a how to use and how it works for the battery management of the FPRA system.

Page 4 of 9

1/23/2009

Battery Management Manual

Revision D01

2 Battery Charge/Discharge/Recharge Concept

First Battery detected System Charge Init System Charge Start System Charge Start Timeout NO Discharge Ubat > Nominal Set Volt

Discharge > 1% Discharge > 1%

Manual Boost Charge Request System Discharge Start

Initial Charge
Manual Boost Charge Request Manual Boost Charge

Manual Boost Charge Request

Time out initial Charge

Battery Test Request System Charge Off Battery Test

Discharge > 1%

Idle Discharge
Discharge > 10% System Discharge NO Discharge System Boost Discharge Time out Boost Charge

Time out Charge NO discharge

Discharge > 1% Discharge > 1%

Discharge > 1% Discharge > 1%

System Charge (const. I)

System Charge (const V)

System Boost Charge (const I)

System Boost Charge (const V)

Ubat > Nominal Set Volt Manual Boost Charge Request

Ubat > (Nominal Set Volt + Boost Volt Offset)

Manual Boost Charge

Manual Boost Charge Request

Recharge

Page 5 of 9

1/23/2009

Battery Management Manual

Revision D01

The Battery state machine mainly consists of five different parts: 1. Initial Charge/Charge Start: after start-up the system is in initial charge state. This state guarantees fully charged batteries before changing to the default operational state. During this time it is not possible to start a battery test. The duration for the initial charge time is user settable and can be changed under System Related Settings Start Charge Time. It is not possible to stop the initial charge cycle in order to start a battery test, but it is possible to schedule a battery test, which starts directly after the initial charge. 2. Charge Off State/Idle State: this is the default operational state. This is the only state, which allows starting a battery test. 3. Battery Test: battery test is a simulated AC-Fail/Discharge State. After a battery test the system will change to discharge state in order to recharge the batteries. 4. Discharge State: Discharging more than 1% and less than 10% of total battery capacity will result in the Discharge State. If AC is back before discharging more than 10% of total capacity the batteries will be recharged without boost voltage. The duration for the recharge is user settable and can be changed under System Related Settings Charge Time. 5. Boost Discharge State: Discharging more than 10% of total battery capacity will result in the Boost Discharge State. After AC is back the batteries will be recharged with boost voltage. The duration for the boost recharge is user settable and can be changed under System Related Settings Boost Charge Time Manual Boost Charge State: A manual started Boost Charge can be performed during a normal charge or during Charge Off State.

State changes from Charging States or Charge Off State requires a discharge of more than 1% of overall battery capacity. Depending on the overall battery capacity this may take several minutes.

Page 6 of 9

1/23/2009

Battery Management Manual

Revision D01

3 The Example System

For a better understanding of the overall battery handling the complete process will be discussed with the help of an example system: 200Ah Battery Block 50% charged at start up -54.5V set Voltage 20A charge limit 20A load no battery test scheduled 2h initial charge time 2h recharge time 3h Boost charge time

3.1

Start-up
During start-up the System operates in the initial charge (also called start charge) cycle: 1. Lowers the System Voltage down to 44V 2. Increase Voltage until the Battery Voltage is reached 3. Increase Voltage until the charge limit is reached This state is called constant current 4. During charging batteries the voltage is raising until the set Voltage of 54.5V is reached (without violating the charge limit) changing to state constant voltage 5. Stay for 2 hours (initial charge time) in constant Voltage 6. Switch to Idle (also called Charge Off) state The initial charge guarantees fully charged batteries before switching to the normal operation state. This allows a much more accurate handling of batteries during the normal system operation. During start up/initial charge it is not possible to start a battery test. It is also not possible to cancel or stop the initial charge.

3.2

Idle/Charge Off
The normal operation state is called Idle or Charge Off State. This is the only state, which allows battery tests.

Page 7 of 9

1/23/2009

Battery Management Manual

Revision D01

3.3

Discharge/Boost Discharge
If the AC fails and the batteries are discharge for more than 1% of their capacity (2Ah for the example system) the system switches its state to Discharge: 1. AC-Fail 2. Discharge Batteries for more than 1% of their capacity 3. Switch to Discharge State 4. 30min discharge (5Ah discharge) 4. 3hours discharge (60Ah discharge) system Voltage follows the battery Voltage system Voltage follows the battery Voltage 5. Stay in discharge state 5. Switch to boost discharge state If the discharge is greater than 10% of the overall capacity of the batteries the system will switch to boost discharge state.

3.4

Charge/Boost Charge
On AC back, the system will switch to the charge or boost charge state. This depends on the state reached within discharge cycle. 1. AC back switch to charge state 2. Increase Voltage until charge limit is reached constant current 3. During charging batteries the voltage is raising until the set Voltage of 54.5V is reached (without violating the charge limit) changing to state constant voltage 4. Stay for 2 hours (charge time) in constant Voltage 5. Switch to Idle (also called Charge Off) state 1. AC back switch to boost charge state 2. Increase Voltage until charge limit is reached constant current 3. During charging batteries the voltage is raising until the Boost set Voltage of 54.5V plus Boost Offset (user settable) is reached (without violating the charge limit) changing to state constant voltage 4. Stay for 3 hours (boost charge time) in constant Voltage 5. Switch to Idle (also called Charge Off) state

If not required, the complete boost discharge and charge handling can be disabled. If disabled, only the normal discharge and charge handling is used.

Page 8 of 9

1/23/2009

Battery Management Manual

Revision D01

3.5

Battery Test
A Battery Test simulates an AC fail and measures the related data: Test Start Time Test Duration Average Current Average Temperature Discharged Ah Test End-Voltage

With the measured data and the user provided test thresholds (Duration, Ah to discharge, Fail Voltage, Warning Voltage) a result is calculated. 1. Start Battery Test 2. Rectifier Voltage is decreased down to -40V simulates an AC fail 3. From now on the handling (discharge and charge) is completely the same as if a real AC fail occurs. Since there is no difference in battery handling between a Battery Test and a real AC fail, each AC fail triggers a Battery Test, a so-called AC-Fail Test. There is only one difference between a real Battery Test and an AC-Fail Test: if the AC supply is back during an AC-Fail Test, the test is countered as stopped with no valid result.

Page 9 of 9

1/23/2009