BOOSTCAP® Energy Storage Modules for Heavy Duty Transportation Applications (BMOD0063 - 125V) - 17 Pages

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BOOSTCAP® Energy Storage Modules for Heavy Duty Transportation Applications (BMOD0063 - 125V)

Catalog excerpts

for Heavy Duty Transportation Applications User Manual for 125 V Modules: BMOD0063 P125 B11 21 (revision 2.1) ǧ BMOD0063 P125 B21 21 (revision 2.1) >

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DANGER HIGH VOLTAGE HAZARD! Never touch the power terminals as the module can be charged and cause fatal electrical shocks. Always check that the module is fully discharged before manipulating the module. Please refer to the step by step instructions in the Safety section of this manual for the manual discharge procedure. WARRANTY LIMITATION Do not open or modify the module. Opened or modified modules are no longer covered by warranty and are unserviceable property of the customer. > The 125 V heavy transportation modules are self-contained energy storage devices comprised of 48 individual...

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1. Heavy Transportation Module 2. Fan Shroud Assembly (12V or 24V) 3. Accessory Kit (including junction box) 4. Users Manual If the unit is found to be defective or any parts are missing, contact the factory. A Return Material Authorization (RMA) number must be issued prior to returning the unit for > The heavy transportation modules can be mounted in two orientations and requires the proper hardware to be used. The two supported orientations are: ҧ Horizontal, straight. Vertical, on the longer side. For this orientation, the module needs to be bolted to the supporting wall. The mounting...

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The 125 V module is installed onto the vehicle first, then the fan shroud assembly is installed onto the module with screws provided. The handles may then be removed if desired but the original mounting screws need to be re-assembled after removal of the handles. Refer to Figures 3.2 for exploded views of the modules and fan shroud assemblies. Re-assembly of the fans in the opposite direction in order to provide reversed air flow is at this point neither recommended nor supported. Note: The mounting envelope is specified in order to provide adequate space for cooling air to enter and exit...

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To provide the lowest possible equivalent series resistance (ESR) the high-power current path within the heavy transportation module is not fused. Care should be taken within the application to prevent excessive current flow as required. Excessive current and/or abnormal duty cycle will result in overheating the module which will cause irreparable damage. Please consult the specific data sheet for each module for current and duty cycle capabilities. Note: The chassis of the module must be connected to system ground through the earthing stud (located on right side of the module, see figure...

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Figure 3.3 Junction box with 2 holes. 3) Install the 2x M25 fittings in the holes. > Figure 3.4 ֖ fitting assembly 4) Trim the power cables (not provided) at the appropriate lengths. 5) Install the junction box housing and fasten it to the front panel using the 8x M5 screws and #10 washers with a 6 Nm torque. Apply Loctite 271 (provided) to screws before installing. > Page 6 User Manual 125 V version 2.1 ֖ Doc. No. 1013688.1 2008 Maxwell Technologies, Inc. ɮ size="-3">

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Figure 3.5 junction box assembly on the module 6) Insert both cables in the junction box (or alternatively through the lid for front installation) through the fittings. > Figure 3.6 ֖ customer cables insertion in the junction box 7) Install the 90 swivel adapters at both terminal locations on the front panel of the module. Swivel adapters are required because cable lengths are short or un-precise and allow mechanical relief of the assembly. This step is not required for front installation. > User Manual Ж 125 V version 2.1 Doc. No. 1013688.1 Page 7 ֩ 2008 Maxwell Technologies, Inc. size="-3">

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Figure 3.7 swivel adapters insertion in the junction box 8) Crimp the lugs onto both cables. When connecting multiple units together, make sure that both ends of the cables are installed in both junction boxes prior to crimping. 9) Depending on the location of holes, creepage and clearance distances between the 2 terminals might be too short and require extra isolation. To maintain the proper creep age distance for an operating voltage of 1000V, we recommend at least 19.1 mm through air. For this purpose, install and clip the plastic covers around both cable lugs. This step is not required...

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Figure 3.9 final connector assembly 11) For the side assembly, tighten the 2 fittings to ensure proper stability and water resistance of the assembly. For the front assembly, it is recommended to measure the length of the section of cables inside the junction box to make sure they will properly fit and provide enough slack. Then unplug the pin power connectors, tighten the 2 fittings and re-plug the pins at both power terminal locations. 12) Install the lid and tighten the 4x M4 screw and washers with a torque of 3 Nm. Apply Loctite 271 (provided) to screws before installing. > Figure 3.10...

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Connection of modules in series or parallel should be done with the same gauge wire as determined for final output connections. When connecting in series connect the positive output terminal of one module to the negative output terminal of the next module. Parallel arrangements require tee connections in the cable (not supplied). Up to twelve (12) 125 V modules may be connected in series for high voltage applications. This corresponds to a maximum system voltage of 1500 VDC. Isolation of the modules is tested to 4000 VDC. The modules should not be used in higher voltage environments. If...

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User Manual ږ 125 V version 2.1 Doc. No. 1013688.1 Page 11 ֩ 2008 Maxwell Technologies, Inc. > size="-1">

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V > total = V > m1 + V > m2 Where: V > total is the measurement from the positive input to the negative output of the module V > m1 is the measurement from the positive input to the center tap. V > m2 is the measurement from the center tap to the negative output. Every pack will have a unique separation of the two halves due to differences in cell capacitance, interconnect resistance variances, initial state of charge separations, native cell leakage current variations and other known contributions. Therefore, the pack should be measured for its baseline condition, which should have a...

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