Battery Management Manual Revision D01

FPRA
Flexi Power Rectifier
Battery Management Manual

Revision D01

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Battery Management Manual Revision D01

History:

Date Version Author Change Notes

23.01.09 D01 Daniel Kreuzer Creation of document

Authors:

Daniel Kreuzer daniel.kreuzer@emerson.com

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

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Content

1 Overview .................................................................................................................................. 4
2 Battery Charge/Discharge/Recharge Concept .................................................................. 5
3 The Example System .............................................................................................................. 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

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1 Overview

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

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2 Battery Charge/Discharge/Recharge Concept

First Battery detected Ubat > Nominal Set Volt

System Charge System Charge

Init Start

System Charge
Start Timeout

NO Discharge
Discharge > 1%

Discharge > 1%

Manual Boost Charge Request

System
Discharge Start

Time out initial Charge

Manual Boost Charge Request
Initial
Charge

Manual Boost
Battery Test Request
Charge Request
Manual Boost System Charge
Battery Test
Charge Off

Discharge > 1%

Idle
Discharge Time out Boost Charge

Discharge > 10%

System System Boost

Discharge Discharge
Time out Charge

NO Discharge
NO discharge

Discharge > 1%
Discharge > 1% Discharge > 1% Discharge > 1%

System Charge System Charge System Boost System Boost

(const. I) (const V) Charge (const I) Charge (const V)

Ubat > Nominal Set Volt Ubat > (Nominal Set Volt + Boost Volt Offset)
Manual Boost
Charge Request
Manual Boost
Charge
Manual Boost Charge Request

Recharge

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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.

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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.

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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 1. AC back switch to boost charge state

2. Increase Voltage until charge limit
reached constant current
3. During charging batteries the voltage
raising until the set Voltage of 54.5V
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
is 2. Increase Voltage until charge limit is
reached constant current
is 3. During charging batteries the voltage is
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.

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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.

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