Battery Management Manual Rev AB Guide

Flexi Power Rectifier FPRB
Battery Management
Manual
Flexi Power Rectifier
Revision AB
Manufactured by: Artesyn Embedded Technologies

Manufacturing PN: AA27540L
Visit us @ http://www.artesyn.com/
Battery Management Manual Rev AB
Page 1 of 9
History:
Date
DD.MM.YYYY
Version
Author
Change Notes
30.10.2013
AA
Ferdinand Sisracon
30.06.2014
AB
Alex Ding
Creation of document for Flexi Power

Rectifier
Change the brand from Emerson Network
Power to Artesyn Embedded
Technologies
Author:
Ferdinand Sisracon
e-mail: Ferdinand.Sisracon@Artesyn.com
Abbreviations:
tbd
GUI
DDU
PDA
MAC
SNMP
Genset
IP
LCD
CU
PID
VPN
to be done
Web-based User Interface
DC Distribution Unit
Power Distribution Assembly
Media Access Control
Simple Network Management Protocol
Generator Set
Internet Protocol
Liquid Crystal Display
Control
Product Information Data
Virtual Private Network
Related Documents:
FPRB User Manual Rev AC by Ferdinand Sisracon: A how to use and how it works for the Webbased User Interface and for the LCD Front-Panel Display of the Flexi Power Rectifier system
Page 2 of 9
Content
Battery Management Manual ............................................................................................................ 1
Flexi Power Rectifier ........................................................................................................................... 1
Revision AB ........................................................................................................................................... 1
1
Overview ........................................................................................................................................ 4
Battery Charge / Discharge Concept ................................................................................................. 5
Flexi Power Rectifier System Sample Configuration .......................................................................... 7

3.1
Start-up ..................................................................................................................................... 7
3.2
Idle/Charge Off .......................................................................................................................... 7
3.3
Discharge/Boost Discharge ......................................................................................................... 8
3.4
Charge / Boost Charge................................................................................................................ 8
3.5
Battery Test ............................................................................................................................... 9
Table of Figures
Figure 2-1 Battery Charge and Discharge Concept.................................................................................. 5
Page 3 of 9
Overview
This document is a how to use and how it works for the battery management of the Flexi
Power Rectifier system.
Page 4 of 9
Battery Charge / Discharge Concept
Figure 2-1 Battery Charge and Discharge Concept
Page 5 of 9
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.
Note:
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 which may
take several minutes.
Page 6 of 9
Flexi Power Rectifier System Sample Configuration

For a better understanding of the overall battery handling the complete process will be
discussed with the help of an example system:
3.1
200Ah Battery Block 50% charged at start up

-53.5V for set Voltage
20A charge limit
20A load
no battery test scheduled
2h initial charge time
2h recharge time
3h Boost charge time
Start-up
During start-up the System operates in the initial charge (also called start charge) cycle:
1.
2.
3.
4.
5.
6.
Lowers the System Voltage down to 44V

Increase Voltage until the Battery Voltage is reached
Increase Voltage until the charge limit is reached This state is called constant
current
During charging batteries the voltage is raising until the set Voltage of 53.5V is
reached (without violating the charge limit) changing to state constant voltage
Stay for 2 hours (initial charge time) in constant Voltage
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
3.3
Discharge/Boost Discharge
If the AC fails and 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) system
4. 3hours discharge (60Ah discharge)
Voltage follows the battery Voltage
s
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 boost 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
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
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

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Manufactured by: Artesyn Embedded Technologies