Battery

UP Range
Technical Manual

GREEN & SAFE SALT BATTERY

 Technical Manual – UP series

Index:
1 GENERAL INFORMATION ........................................................................................................... 4

1.1 Introduction ........................................................................................................................... 4

1.2 Purpose .................................................................................................................................. 5

1.3 Related Publications ............................................................................................................. 5

2 SAFETY ......................................................................................................................................... 6

2.1 Battery Safety ........................................................................................................................ 6

2.2 Warnings ................................................................................................................................ 6

2.3 Site conditions caution ......................................................................................................... 7

2.4 Safety Precautions ................................................................................................................ 7

2.5 Required Safety Equipment ................................................................................................. 7

3 HANDLING PROCEDURES .......................................................................................................... 8

3.1 Unpacking and Inspections .................................................................................................. 8

3.2 Handling ................................................................................................................................. 8

3.3 Storage ................................................................................................................................... 8

3.4 Battery Return and Disposal ................................................................................................ 9

3.5 Packaging .............................................................................................................................. 9

3.6 Transportation ..................................................................................................................... 10

4 BATTERY INSTALLATION ......................................................................................................... 11

4.1 Tools and Hardware Required ........................................................................................... 11

4.2 Battery Layout and Mounting Orientation......................................................................... 11

4.3 Battery Front Panel ............................................................................................................. 13

4.4 Power Cable Connection .................................................................................................... 14

4.5 Data Cable Connection ....................................................................................................... 15

4.6 USB receptacle to allow connection for service operation ............................................. 16

4.7 Ground connection ............................................................................................................. 17

4.8 Battery activation ................................................................................................................ 17

4.9 Battery in parallel operation ............................................................................................... 18

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4.9.1 Parallel charge .................................................................................................................. 19

4.9.2 Parallel discharge ............................................................................................................. 19

5 BATTERY IN OPERATION ......................................................................................................... 20

5.1 Battery Warm-Up ................................................................................................................. 20

5.2 Battery Charging ................................................................................................................. 20

5.3 Floating ................................................................................................................................ 21

5.4 Discharging and Rated Capacity ....................................................................................... 21

5.5 Battery Cool Down .............................................................................................................. 21

5.6 Battery Internal Resistance ................................................................................................ 22

5.7 Maintenance Free ................................................................................................................ 22

6 TECHNICAL INFORMATION ...................................................................................................... 23

6.1 FZSoNick Battery Description ............................................................................................ 23

6.1.1 BMS Functions ................................................................................................................. 23

6.2 Battery Specification ........................................................................................................... 24

6.3.1 Front Label ........................................................................................................................ 25

6.3.2 Side BMS Label ................................................................................................................ 25

6.3.3 Top Label .......................................................................................................................... 26

6.4 Battery Alarms ..................................................................................................................... 27

6.6 Extended Outages ............................................................................................................... 28

6.7 Light Emitting Diodes (LED’s) Explanation ...................................................................... 28

6.8 Safe Technology .................................................................................................................. 29

6.9 Battery Protection ............................................................................................................... 29

6.9.1 Electrical Protection ......................................................................................................... 29

6.9.2 Battery Thermal Protection ............................................................................................. 29

6.9.4 Mechanical Protection ..................................................................................................... 29

6.9.5 Reliability .......................................................................................................................... 29

6.10 Technical Assistance ........................................................................................................ 29

APPENDIX ...................................................................................................................................... 30

APPLICATION NOTES .................................................................................................................. 30

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English FZSoNick

1 GENERAL INFORMATION

1.1 Introduction

The FZSonick UP battery range is a group of batteries designed for energy backup applications.
Each module of this range is a complete battery system, assembled with Sodium-Metal Chloride
cells arranged in strings according to Table 1:

UP Battery Model 110UP80 125UP80 130UP80 220UP40 250UP40

Nominal Voltage [Vdc] 110 125 130 220 250

Charge Voltage Range

121.0 - 160 135.1 - 160 140.5- 160 243.2 - 300 270.2 - 300
[Vdc]

Min Voltage [Vdc] 88 100 104 180 200

80Ah 80Ah 80Ah 40Ah 40Ah

Nominal Capacity (C4)
8.5kWh 9.6kWh 9.9Wh 8.6kWh 9.6kWh

Cells 88 100 104 90 100

Configuration 44S 2P 50S 2P 52S 2P 90S 1P 100S 1P

Table 1: Battery Model configuration

A battery module is an assembly of a Battery Management System (BMS) and the relevant Battery
pack.

Battery
Management Battery Pack
System

Figure 1

The BMS manages all the battery functions and ensures a reliable and safe operation.
The battery pack is provided with internal electric heaters, to achieve and maintain the internal
working temperature of 265°C. The thermal insulation of the battery pack is such that, with an

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 Technical Manual – UP range

internal temperature of 265°C, the surface temperature of the enclosure is just 10 to 15°C above
the environment.

1.2 Purpose

This manual provides information required to install and operate the FZSoNick UP batteries.
Anyone involved in handling, installing or using the FZSoNick UP Batteries must read and
understand this manual.

1.3 Related Publications

Publication Name Publication Number

SDS FZSoNick Battery 04-2017 IT
SDS FZSoNick Battery 04-2017 EN
SDS FZSoNick Battery 04-2017 DE
Battery safety data sheet
SDS FZSoNick Battery 04-2017 ES
SDS FZSoNick Battery 04-2017 FR
SDS FZSoNick Battery 04-2017 PT

Monitoring Software Manual NA

Battery ModBus Protocol NA

Battery CanOpen Protocol NA

Table A

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2 SAFETY
2.1 Battery Safety

This manual contains important instructions that should be followed during installation and operation
of the FZSonick Battery Module.
The battery is designed to operate safely and to protect personnel from danger. Because it is an
industrial product, however, the battery may cause risk to personnel, equipment or facilities if not
handled properly.
The hazardous materials found in the battery are sealed inside the battery’s case. Under normal
operating conditions, this design is intended to help protect the user from the risk of injury.

If multiple layers of the battery are breached or the battery ruptures, extra care must be
taken. Refer to the Battery Safety Data Sheet (SDS) for instructions on how to manage
these extreme conditions.

The following guidelines should be followed when handling and operating the battery under normal
circumstances.

This battery should only be installed and operated by qualified personnel.

If you have any questions regarding safety for this product, please refer to section 5.11 of
this manual

Unlike traditional batteries, this Sodium Metal Chloride battery can be charged or
discharged only when the internal temperature reaches the operative value. Whenever
the internal temperature is below, the battery acts as a passive device.
Before use, be sure to fully understand the battery functionality described in this manual

2.2 Warnings
A battery can present a risk of electrical shock. The following precautions should be observed when
working on batteries and energy storage systems:

 Remove watches, jewelry, rings and other metal objects.

 Use tools with insulated handles

High voltages may be present within this unit even when it does not appear to be
Operational. Observe all cautions and warnings in this document.

As for Electromagnetic compatibility (EMC) the battery is tested and certified for general industrial
applications.

In a domestic environment, this product may cause radio interference

In case the current drawn by the inverter from the battery presents a prevalent half wave variable
profile the user shall consult the battery supplier to apply appropriate filters to mitigate it,
otherwise the warranty is void.
As an example this situation has been found in three-phase inverters with capacitor midpoint topology and
unbalanced loads.

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2.3 Site conditions caution

Install and operate the battery in an indoor or enclosed environment only in an ambient temperature
range of -20°C to +60°C. Install it in a clean environment, free from conductive contaminates,
flammable liquids or gases.
The installation site must have a properly rated and tested grounding system.
Ventilation for outgassing or cooling is not required. Each FZSonick Battery module will dissipate
average of 115 Watts of heat under normal operation, which may affect room or cabinet ventilation
design.
The installation site should be clear of obstructions. The installation team should understand the
route that personnel and equipment will take when moving the batteries into position.

DO NOT open or damage sealed batteries.

For additional information, refer to the battery Safety Data Sheet (SDS).

2.4 Safety Precautions

To prevent damages to the batteries and personal injuries, following safety instructions need to be
followed all the times:
 Do not install the battery if you notice physical damage
 Do not place the battery upside down, on a side or with the BMS facing down
 Do not pack the battery when it is hot
 Do not expose the battery to temperatures above 90°C (194°F) or below -40°C (40°F)
 Do not allow metal objects to rest on the battery
 Remove rings or metal wristbands when working with the battery
 Use insulated tools to install the battery
 Use all the handles when handling the battery

2.5 Required Safety Equipment

The following safety equipment should be available on site. Check local safety codes and
standards to determine if additional equipment is required.
 Safety rated eye protection
 Hearing protection
 Electrically insulated gloves
 Flame-retardant clothing (8 cal/cm2)
 Electrically insulated/impact resistant footwear
 Electrically insulated tools

Verify the requirement with the AHJ (Authority Having Jurisdiction) to determine if
additional equipment is required.

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3 HANDLING PROCEDURES
3.1 Unpacking and Inspections

FZSoNick carefully tests and inspects the battery before shipment. Upon receiving a shipment of
batteries, open the wooden crate box and check the battery and hardware against the packing list.
Report any damage immediately to the carrier if the shipment shows signs of damage in transit.
Also notify your FZSoNick customer service representative.

3.2 Handling

The use of certified non-conductive tools is highly recommended.

High energy batteries should always be handled carefully to avoid the possibility of creating a short
circuit. In some circumstances, when in operation, the battery surface may be hot.
Battery handles are for hand carrying only, do not sling from the handles. Use an appropriate battery
lifting harness for hoisting the battery. The battery lifting handles are to be used to remove the battery
from its original packaging and to securely place the battery in its operating location. Always use all
handles when handling the battery.
Never push the battery by applying force to the Battery Management System front panel.
Personnel should inspect the nearby environment where batteries will be handled to identify and
eliminate all potential sources of electrical and physical damage to the batteries. Avoid conditions
that could result in short-circuits, overheating, puncture or crush.
During cool down period is possible to handle the battery (maximum tilting 30°) if battery internal
temperature is >200°C, typically within 12h from battery switch off. Shipping is possible only when
the battery internal temperature is <90°C, typically after 72h from battery switch off.
When the battery is cold (all internal materials are in a solid state), a temporary placement with
angles greater than 30° is allowed. In any case, never place the battery on its power terminals,
upside down, with the front cover facing down or on its sides.

Lifting handles

Extraction handles

Figure 2

3.3 Storage

The best environment to store the FZSoNick battery system is a cool, dry, and well-ventilated
location, in a properly identified warehouse area.
The battery can be stored for any length of time in the cold state without changing its
characteristics or state of charge.

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 Technical Manual – UP range

The battery cells have an extremely high resistance in the cold state and even a very low current
can damage the cell when cold. Do not try to disassemble the battery management system (BMS)
and apply any load or perform any measurement using the internal terminals of the battery.
The storage conditions should be temperature between –40°C and +60°C, Relative Humidity (non-
condensing) max 90%

3.4 Battery Return and Disposal

A Sodium Metal Chloride battery must be transported cold and, if possible, discharged.
Do not burn or dispose of the battery. End of life or defective batteries are to be returned to FZSoNick,
where recycling and/or disposal of the different parts will be performed.
Notify FZSoNick customer service prior to returning the battery.

As soon as the battery power connector is unplugged, the internal temperature starts
to decrease. The minimum cool down period since the power plug disconnection to
allow the transportation is 72 hours for the complete solidification of the internal materials.

3.5 Packaging

The battery is shipped cold and completely discharged in a wooden crate fixed with straps to avoid
any risk of uncontrolled movement or drops and surrounded by a protective foam cushion (fig.3,
dimensions in mm).
In case of battery return, battery should be packed in the original wooden box, only when turned off
and cold. Battery with a heavily damaged external case should be wrapped with polyethylene sheets
before of the packing, to avoid the risk of release of material or odors.
The package should include the relevant safety information for the transport: please contact
FZSoNick for the details.

Figure 3

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3.6 Transportation

Anyone who is engaged in shipping Sodium Metal Chloride batteries must comply with all the rules
and regulations listed below.

UN number: 3292 “Batteries or cells containing sodium”

4.3 “Water reactive substances” In contact

Class:
with water produces flammable gas

Packing group: Il Materials of medium danger

433 For air shipment

Packing instructions: P408 For road shipment
IMDG For sea shipment

Kemler nr: Not Identified

ERG: 4W

Protect from humidity and water

Particular caution:
Handle with care
Table B

Transport classification conforming to the following specific regulations:

For road or rail transport ADR/RID (SDR)

For air transport lATA

For sea transport IMDG

Table C

Use ADR vehicles only if the gross weight for each transport unit is > 333 kg.
During air transport: use only cargo flight.
Conforming to the regulations, the batteries are transported:
 at ambient temperature with the sodium at the solid state, typically after 72h from battery
switch off.
 labeled and packed conforming to international rules (ADR, IATA, IMDG)
 not charged.

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 Technical Manual – UP range

4 BATTERY INSTALLATION

4.1 Tools and Hardware Required

 Insulated 13mm socket and a torque wrench 5-10Nm (3 -7Ft-Lbs. or 10 - 88 in-Lbs.);

 Insulated wrench set;
 Multi-meter.

4.2 Battery Layout and Mounting Orientation

An FZSoNick battery, when active, contains some materials in a liquid form. Even though the battery
is fully sealed, for best performance the maximum permanent inclination, when installed, is 30
degrees.
During handling when the battery is cold (all internal materials are in a solid state) a temporary
placement, with angles greater than 30° is allowed.
In any case, never place the battery on its power terminals or upside down or with the front cover
facing down or in its sides.
The battery must stand on a flat mechanical support that has to cover at least 50% of the battery
footprint .Provide adequate shelf loading capacity, ensure that there is sufficient aisle space and
avoid short-circuits between the battery connector terminals and the shelf's metal parts.

Max 30°

Figure 4A Figure 4B

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English FZSoNick

The battery must be properly locked to the shelf, ensuring complete mechanical stability.
Fixing points are indicated in the following picture:

A: Lifting handle

B: Panel lip

Figure 5

Point Item Suggested operation

A Lifting handles Fasten to the structure by means of ties
B Lateral panels lip Lock to the structure by means of clamps
Table D

Never drill, weld or modify battery surface to lock it to structure

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4.3 Battery Front Panel

The battery power terminals and interface ports are located in the battery management system of
the battery as indicated in the fig.6. All the connections of the battery are described in the Table E.

4
2
2
3
3
1
1

Figure 6

Item Description Function Type

1 Battery power terminals MS3102 to

Power connector, J1BS
connection to the DC Bus MIL-DTL 5015 Series I

2 Communication. Alarm MS3110 to

Data Connector, J2BS
contacts. EPO input MIL-C-26482 Series I

3 USB, J3BS Service port USB Type A

4 HMI Battery status display LED

Table E

The IP rating of the battery is guarantee only if all the plugs are properly screwed in.

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4.4 Power Cable Connection

Do not connect batteries in series. Parallel connection is allowed.

Each SMC battery is to be considered as VDC battery system.

Power cable connector is identified with the name J1BS (label A, section 6.3.2).
It includes the power connection of the battery, the emergency load disconnect input and the
shutdown input pins as indicated in the table D and figure 5.

Figure 5

Contact Connector
Contact Contact
Identification Contact size
function type- P/N P/N
AWG
Battery positive
A 4
terminal
J1BS
safe
B 12 HVIL
disconnection
ACC02A24-
Battery Negative
C 4 12P(072)(SP)
terminal

external booster
D 12 HVIL
power supply (-)

external booster
E 12 HVIL
power supply (+)

Table D
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4.5 Data Cable Connection

Data cable connector is identified with the name J2BS (label B, section 6.3.3)
It includes the CANbus and MODBUS connections with the pin out indicated in the table E and
figure 6.

Figure 6

Connector Contact Contact size Connector

Identification ID
function function AWG P/N

J2BS CAN L A

CAN H B

MODBUS+ C

MODBUS – D

ALARM DRY
E
Battery CONTACT- NC
network ALARM DRY To suit 0.5 mm^2 LPT02SE-
F
connection CONTACT- COM cable 12-10P(072)
REMOTE
POWER OFF G
+5Vdc
REMOTE
POWER OFF H
GND
ALARM DRY
K
CONTACT- NO
GND J

Table E

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4.6 USB receptacle to allow connection for service operation

The USB receptacle to allow connection for service operation is identified with the name J3BS
(label C, section 5.3.4)

Fig.7, J3BS connector

Connector Contact Contact size Connector

Identification ID
function function AWG P/N

J3BS 1

2
Service
USB UA-20PMFJ-
Operation
NC7001
3

Table F

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4.7 Ground connection

The UP battery is equipped with a ground connection located on the front side of battery pack
close to the BMS connectors (Fig.8)

Ground Connection
Diameter Length
M8 16 mm

Fig.8, Ground Connection

4.8 Battery activation

1) Connect J1BS and ground wire. Data connection (J2BS) in not mandatory.
2) Set the DC power supply at the charge voltage indicated in table 1. No current limitation is
needed however, with the factory setting, a minimum current supply per battery is necessary to
ensure the shortest charging time. Please refer to table 1.
3) Turn on the DC power supply
4) If the battery internal temperature is below 265°C (509°F) the warm up phase is started, (see
section 5.1 of this manual) till the target temperature is achieved. At this point the battery main
contactor is closed, connecting the battery pack to the DC power supply.
5) Now the battery is electrochemically operative and, if it is not in the full state of charge, the built-
in battery charger turns on and the charging phase starts. (See section 5.2 of this manual).
6) A discharge is always possible, even if the battery is in charge mode (see section 5.4 of this
manual).

When an SMC battery is off, it is always necessary to connect it to a powered DC bus

to turn it on again, for any SOC and any internal temperature condition.

If the voltage at the terminals of the battery power connector exceed the maximum
specified limit for the battery, an alarm is issued and, depending on the voltage level,
the battery may be permanently damaged. Do not connect the battery to a power
source where the voltage or voltage spikes may exceed the maximum allowable
battery voltage.

Battery must be activated and charged using a constant voltage power source.

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4.9 Battery in parallel operation

In order to achieve the required level of energy two or more battery modules can be connected in
parallel.
Parallel power connection is defined such that all the positive battery terminals (pin A of the J1BS
connector) are connected to the same rectifier positive terminal and all the negative battery terminals
(pin C of the J1BS connector) are connected to the same rectifier negative terminal.
Wire lengths should be the same for all modules to have even discharge between them.

Power cables should have the same length

J1BS(power) J1BS(power) J1BS(power)

Battery #1 Battery #2 Battery #n

Figure 10a

Battery #1 Battery #2 Battery #n

To Positive DC
terminal of the
rectifier

To Negative DC
terminal of the
rectifier

Safe disconnection
Figure 10b jumper

Safe disconnection jumper is necessary to activate the battery.

FZSonick standard wiring already include this jumper, located in the connector plug.

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4.9.1 Parallel charge

When the batteries are connected to the same DC rail, all their positive terminals are at the same
potential and all their negative terminals are at the same potential.
Since the BMS is equipped with a charge regulator, all of them have the same voltage input but they
individually manage the charge phase of the relative battery pack.
Battery charger is designed to work permanently connected to a constant voltage source and it
regulates the voltage and the current as a function of the SOC: when in parallel, if the batteries have
different SOCs, the system tends to an even situation thanks to the individual regulation.
Due to the voltage levels and the BMS circuit design, current circulation between batteries is not
possible during a charge phase, as shown in figure 11.

Rectifier BMS BMS Load

Figure 11

4.9.2 Parallel discharge

When the DC bus voltage becomes lower than the battery voltage, the battery immediately enters in
discharge phase. Due to the BMS design there is no delay in the power delivery.
In a discharge phase with a parallel connection, individual battery current may be slightly different
due to different internal resistances or to the presence of different connection residences and so, at
the end of the discharge, batteries could show slightly different final SOCs. This uneven situation is
recovered during the subsequent charge, thanks to the individual charger topology.
With a given load power, current circulation between batteries during a discharge is impossible due
to the level of internal resistance and the presence of the internal charge regulator. Even if a battery
disconnects before the other of the parallel, that battery cannot enter the charge phase, due to the
low voltage applied to the charger input.

BMS BMS Load

Battery 1 Figure 12 Battery n

Maximum number of batteries that can be connected in the same data chain is
64 with the RS485.
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5 BATTERY IN OPERATION

5.1 Battery Warm-Up

The FZSoNick battery needs to be warm up before it starts to deliver energy since it operates
between 265° and 350°C (509-662°F).
The BMS performs the warm-up process automatically as soon as the battery is connected to a
powered DC BUS. When the battery is in the warm-up state both green and blue LEDs will blink.
Starting from room temperature, this process takes >12 hours. A graph of the process is included in
the appendix I section. Power consumption during this process is indicated in the Table J.

Elapsed Time (h) Temperature (°C) Power consumption (W)

0 25 380
7 160 380
12 260 380
>12 265 115
Table J

Power consumption values in the first three lines in Table J are during the warm-up
phase of operation. Whenever the battery SOC is lower than 100%, the battery will
automatically Start the charge cycle after the warm-up condition. After the charge cycle
the Power consumption of the battery remains constant. The exact value is affected by
ambient temperature. See Appendix for details.

5.2 Battery Charging

The BMS of the battery is equipped with an integrated charge regulator, basically a DCDC step-
down (Buck) converter. A specific battery accepts any voltage in the range indicated in table 1 , and
regulates the charging current and the charging voltage of each string to the optimal levels.
Recharge current is limited by the BMS, therefore there is no need to limit the current at the rectifier
level. To charge the battery, a simple DC power supply can be used. In any case the BMS is fully
compatible with most of the rectifiers or UPS available in the industrial market.

If the BMS detects the SOC of the battery is below 100%, the charge phase is automatically
started. This is indicated by the blue LED which will turn solid on.

Battery recharge time depends on the current availability and the initial SOC. If the full current is
available, a complete charge takes approximately 12hrs. More charging information is included in
the appendix II section.

If the available current is below the value indicated in table 1, during the first part of the
charge process, the DC Bus voltage could decrease below the minimum value. A
warning could be issued by the BMS. Besides the factory setting, lower current settings
are available on request.

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5.3 Floating

When a fully charged battery is connected to the DC bus (with only green led solid on) the internal
charge regulators are switched off. In this condition the Battery “float” current is the sum of two
main parts.
The first one is due to the power consumption of the electronics controller and the second is due to
the power consumption used to compensate for the heat losses.
The first component of the float current is constant over the battery status while the second
depends on battery working conditions. (i.e. ambient temperature).
The average float power consumption at 25°C is 115W; more detailed information is available in
the appendix III section of this manual.

5.4 Discharging and Rated Capacity

A discharge is always possible in case the battery is in float or charge state, when the green LED
is on solid. When the battery is performing a warm-up or is an alarm condition a discharge is not
possible (green LED blinking).
In case the battery goes into discharge, the yellow LED turns on solid and, when the state of
charge of the battery is under 12,5% of its nominal capacity value this LED turns to a blinking
indication.
The rated capacity of FZSoNick battery are reported in Table 1. At higher rates the capacity is
lower than nominal because of the internal resistance losses; at lower rates the useful capacity is
lower due to the fact that some power is needed to maintain the battery at the internally working
temperature and this power is drawn from the battery itself. The discharge performance is not
significantly affected by temperature variations, especially compared with other battery
technologies. Even if the outside ambient temperature varies greatly, its internal temperature will
remain within the operative range and then the capacity and life are not affected.
Detailed information is available in the appendix IV section of this manual.

The discharge performances of a brand new battery could result slightly lower (5-6% less)
compared to the nominal battery performances described in the appendix IV of this
manual.
FZSoNick technology requires some run-in cycles (10 maximum) in order to reach the
maximum battery performances.

5.5 Battery Cool Down

The battery is kept at its operating temperature with the internal heaters, controlled by the BMS and
it is insulated with special insulation material to limit both the thermal losses and the temperature
gradients inside the battery. If the battery is operative (ON-LINE), the thermal management of the
BMS keeps the internal temperature at a minimum of 265°C.

As soon as the battery is turned off, the BMS is powered off and so the heating elements: the internal
temperature starts to decrease with a typical behavior (see appendix V section for details).
If the battery is removed from the DC bus by an external circuit breaker (Power connector still
plugged) , the battery starts to use its own energy to keep the internal temperature. After a number
of hours, depending on the SOC, the battery turns off (when it’s SOC=0%) and the temperature
starts to decrease.

During cool down period is possible to handle the battery if battery internal temperature is
>200°C, typically within 12h from battery switch off. Shipping is possible only when the battery
internal temperature is <90°C, typically after 72h from battery switch off.

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When the battery is cold (all internal materials are in a solid state), a temporary placement with
angles greater than 30° is allowed. In any case, never place the battery on its power terminals,
upside down, with the front cover facing down or on its sides.

5.6 Battery Internal Resistance

The internal battery resistance varies depending on the different states of charge and model.
Average value are reported in the following tables, see appendix VI section for details.

UP Battery Range 110UP80 125UP80 130UP80 220UP40 250UP40

Typical Internal
Resistance [mOhm] 193 219 228 788 875
Cells in series 44 50 52 90 100
Strings in Parallel 2 2 2 1 1

5.7 Maintenance Free

The FZSoNick Sodium Metal Chloride battery does not require any maintenance.
The battery is designed and manufactured without user serviceable parts.
User interface provides battery statuses and operation data.

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6 TECHNICAL INFORMATION
6.1 FZSoNick Battery Description

The battery’s primary function is to store electrical energy and to supply it to an external load when
needed. The battery management system also provides secondary functions that are essential to
achieve the required service life duration.

6.1.1 BMS Functions

Main functions of the integrated Battery Management System (BMS) are:

 Battery Thermal Management: battery needs to be warm before to receive or deliver energy.
The thermal management of the BMS performs the warm-up process automatically as soon
as it is powered.
 Battery Charge Process: the BMS is equipped with a charge controller which is able to
regulate the charging parameters (voltage and current) in order to obtain the best charging
performance.
 Battery Power/Energy Output Checks: the BMS calculates the battery SOC to provide a
reliable and safe operation and to avoid overcharge or over discharge.
 Battery Operating Conditions Checks: the BMS continuously measures all the battery
parameters such as voltages, currents, temperatures, insulation levels providing a
continuous monitoring of the operating conditions.
 Redundant Control: the controller is equipped with a safety redundant microprocessor for
safe operations.
 Battery communication: the BMS has various communication capability using different
communication ports: USB, RS485 or CAN Bus .

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6.2 Battery Specification

BATTERY TYPE 110UP80 125UP80 130UP80 220UP40 250UP40

Nominal Voltage [V dc] 110 125 130 220 250

Charge Voltage Range [V dc] 121.0 - 160 135.1 - 160 140.5- 160 243.2 - 300 270.2 - 300

Vmin [V dc] 88 100 104 180 200

80Ah / 80Ah / 80Ah / 40Ah / 40Ah /
Nominal Capacity (C4)
8.6kWh 9.6kWh 9.9Wh 8.6kWh 9.6kWh

Max Discharge Current (1’) 120 A 120 A 120 A 60 A 60 A

Max Discharge Current (1h) 60 A 60 A 60 A 30 A 30 A

Power Fuse Rating 150 A 150 A 150 A 100 A 100 A

Thermal Dissipation at 25⁰C 110 W 110 W 115 W 110 W 110 W

Warm-up time at
<13 h <13 h <13 h <13 h <13 h
commissioning

Recharge time
<13 h <13 h <13 h <13 h <13 h
from 0% to 100% SOC

Recharge time
<8 h <8 h <8 h <8 h <8 h
from 0% to 90% SOC

Recharge Current (internally

16 A 16 A 16 A 8A 8A
regulated)

System Communication Port /

RS485/Modbus RTU and CAN/CanOpen
Protocol

HMI 4 LEDs

Local Access Interface USB

IP RATING IP55

F [mm/ in.] 500 / 19.7

H [mm/ in.] 322 / 12.7

D [mm/ in.] 522 /20.6 560 /22.0 598 /23.6 522 /20.6 560 /22.0

WEIGHT [kg / lb] 113 / 249 120 / 264 125 / 275 114 / 251 120 / 264
Operating temperature range
-20°C / +60°C -4°F / +140°F continuous
with full performance
Storage Temperature Range -40 /+ 60°C (-40 / 140°F)

Cell Pack Shelf life with no

20 years
degradation

Battery Expected Service Life 20 years

Table K

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6.3 Battery Labels

The FZSoNick battery has three visible labels located as in the Figure 14:

Front
Top
Label
Label

Warning
Label BMS
Label

Figure 14

6.3.1 Front Label

The label in Fig.15 contains battery technical information, the LED explanation legend and the
interface ports indications.

Figure 15

6.3.2 Side BMS Label

The label in Fig.16 contains the BMS serial number

Figure 16

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English FZSoNick

6.3.3 Top Label

The label in Fig.17 contains battery technical information, the production date and the battery
serial number.

Figure 17

6.3.4 Warning Label

Symbol Description
Keep the battery in the upright position. Do not connect in series two or more
batteries. Parallel connection is allowed.

Hazardous voltage risk of electric shock. Authorized personnel only.

The battery surface may be hot.

The battery is an electrostatic-sensitive device, pay attention during its

manipulation.

Observe operating instructions and display it visibly in the vicinity of the battery.
Work on batteries only after instruction by qualified staff.

Wear eyes protection and protective clothing when working with batteries.
Observe accident prevention regulations.

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6.4 Battery Alarms

Battery management system issues warnings or alarms depending on the battery working
conditions or to the presence of internal faults. Depending on the criticality of the situation, the
Amber LED begins to blink (warning) or the Red LED become solid (Alarm). Alarm code is visible
via SMC Monitor as indicated in the Table below:

Alarm Descr Alarm Alarm

Delay Type Description
Code String Family
0 Tam TEMP NULL REC Ambient Temperature is low
2 TaM2 TEMP LONG REC Ambient Temperature is too high
3 Tbm TEMP SHORT REC Battery Temperature is low
5 TbM2 TEMP SHORT REC Battery Temperature is too high
7 VBm2 V_BUS LONG REC Too Low Voltage on DC BUS
9 VBM2 V_BUS LONG REC Too High Voltage on DC BUS
11 IDM2 DISCH NULL REC Discharge Current is Too High
12 TaM1 HW LONG UNREC Isolation error
15 HTRE HW LONG REC Warmp Up Fault
16 TCPE HW LONG UNREC Thermocouple is not reliable
17 STRE HW LONG REC Voltage measurement circuit fails
18 CM E HW LONG REC Current measurement circuit fails
19 HWFL HW NULL UNREC BMS hardware fails
20 HWEM HW NULL REC Hardware protection system is activated (westinghouse)
21 ThM TEMP LONG REC Heatsink temperature too High
23 vsm2 DISCH NULL UNREC String Voltage Too Low
25 vsM2 V_STR SHORT REC String Voltage Too High
27 iCM2 CHRG LONG UNREC String Charge Current Too High
29 iCM2 DISCH NULL REC String Discharge Current Too High
30 TaM1 V_STR LONG WARN String voltages unbalance warning
31 MID2 V_STR LONG REC String voltages unbalance alarm
32 TaM1 CHRG SHORT WARN Not enough charging power is available on Vbus
33 CCBF HW LONG UNREC Charger Circuit not working
42 HTFS INIT SHORT UNREC Heaters Fuse Blown
43 DATA HW SHORT UNREC Parameter outsize the admitted range
44 TaM1 HW LONG WARN One string out of service
45 LMPA HW LONG UNREC All strings out of service
49 TaM1 CHRG LONG WARN TOC is less than 100% from 2.5 days
50 TOCA CHRG LONG REC TOC is less than 100% from 3.5 days
54 ULAL UL NULL UNREC The Safety microprocessor intervened

6.5 Service Life Definition

The service life of a FZSoNick battery is the period of useful service under the conditions defined in
the battery specification expressed as the period elapsed between the start of life and the time where
the ampere-hour maximum capacity has fallen to 80% of the rated capacity. Even if the battery goes
below 80%, its rated capacity will not drop abruptly and suddenly like other battery technologies.

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English FZSoNick

6.6 Extended Outages

Extended outages don’t have any consequences on the battery health. In case of a prolonged
discharge, the battery disconnects itself from the load when its energy is expended and, if the main
DC supply doesn’t come back, the internal temperature will start to decrease. When cold the
battery is completely inactive and can stand in such condition for a period of time which is virtually
infinite. As soon as the mains return the battery starts the warm up procedure (if needed).

6.7 Light Emitting Diodes (LED’s) Explanation

LED COLOUR INDICATION NOTE / ACTION

Battery ready to operate, The battery is fully charged

SOLID GREEN
connected to the DC bus State of Charge (SOC) =100%

BLINKING GREEN Battery is warming up, Temperature is below operational.

BLINKING BLUE not connected to the DC bus Charging or discharging is not allowed

SOLID GREEN Battery under charge, Battery SOC is < 100%

SOLID BLUE connected to the DC bus Discharging is allowed

SOLID GREEN
SOLID YELLOW
Battery is discharging

SOLID GREEN
BLINKING YELLOW
Battery is discharging Warning Active

SOLID GREEN
Battery is discharging.
SOLID YELLOW
SOLID BLUE Direct charge is allowed

SOLID GREEN
Battery is charging.
BLINKING YELLOW Warning Active
SOLID BLUE Discharge is allowed

SOLID GREEN A warning occurred during

BLINKING RED
Check float (idle) conditions/parameters
the float (idle) condition

SOLID GREEN
A warning occurred while
SOLID BLUE Check charge conditions/parameters
BLINKING RED the battery was charging

SOLID GREEN
A warning occurred while
SOLID YELLOW Check discharge conditions/parameters
BLINKING RED the battery was discharging

The battery was disconnected because of a

Alarm status – the battery
BLINKING GREEN major issue.
SOLID RED
is not connected to the DC
Charging or discharging
bus
is not allowed
SOLID GREEN
SOLID YELLOW Battery is preforming the
SOLID BLUE
The BMS is pre-charging internal circuits
Start-up process
SOLID RED

Check if DC bus is up otherwise, the BMS

NO LED ON the BMS is not powered-up
has to be serviced/repaired

BLINKING GREEN Check Power connection

BLINKING YELLOW
BLINKING BLUE
Recessed contacts open insertion
BLINKING RED
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6.8 Safe Technology

Each battery is made of sodium metal chloride cells in series and parallel. A single cell is composed
by a fully sealed prismatic steel case which contains the active materials and the cell separator. The
cells are electrically connected by brazed/welded rigid inter-cell connectors and the resulting cell
pack is contained into a stainless steel (inner) box together with 3 heating elements and the
temperature probes.
The inner box is surrounded by the thermal insulation complex which is composed by a number of
micro-porous silica panels with the appropriate thickness to provide the right level of insulation,
minimizing the thermal losses.
The outer stainless steel battery box contains the inner box and the thermal insulation barrier and
provides the adequate mechanical strength and a sealed construction.
All of the active materials are safely and permanently contained within the battery, which has zero
spillage and cannot leak or outgas in normal operation.

6.9 Battery Protection

Each battery has its own electrical, thermal and mechanical protection built-in.

6.9.1 Electrical Protection

Electrical protections are considered as primary security.

FZSoNick battery is protected against short circuit or prolonged current overload (current above
nominal will open the positive leg) by the Battery Management System’s (BMS) ability to
disconnect the battery . Battery is also provided with internal fusible link protection, that will open
the negative leg if an over current situation, in the remote case of non-intervention by the BMS,
occurs.
6.9.2 Battery Thermal Protection

Thermal protection devices are used to prevent battery overheating situations. The following is
a list of the thermal protections built in each battery:
 To maintain the battery internal temperature between 265 and 350 °C (509-662°F),
heaters activated by a closed-loop temperature control system, are managed by the BMS.
 The BMS will temporarily disconnect the battery path should its internal temperature exceed
350°C (662°F).
 The BMS will cut power to the battery heaters should the battery temperature be above
350°C (662°F).

6.9.4 Mechanical Protection

Batteries are packed with a double stainless steel case and cells are hermetically sealed with
metal cases which fully enclose the active materials and which are so constructed and closed to
prevent the release of the active materials under normal conditions.

6.9.5 Reliability

A battery failure in a multi-battery installation will not cause the battery backup system to fail nor
will it cause the other batteries to malfunction. The defective battery will take itself off-line from
the other batteries. Power to the load will not be compromised with the only effect being a
reduction in the backup time.

6.10 Technical Assistance

For technical assistance or any questions concerning FZSoNick or any of its products, contact
FZSoNick customer support.
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English FZSoNick

APPENDIX
I - Warm Up Process

The graph below shows the internal temperature evolution of a battery during the warm-up process

II - Battery Recharge

The battery can be recharged using a constant voltage DC power supply. Excess of charging
capacity is not a concern because internal battery circuitry automatically limits the charging current
(8A or 16A depending on the battery model) to ensure the safe and optimum operation of the battery.

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The graph below shows the recharge time for various initial states of charge. These results can be
obtained when the recharge power required by the battery (standard setting) is fully available from
the rectifier.

Recharge time [h] [-20 + 60°C; -4 ÷ +140°F]

Final SOC (%)
25 50 75 100
Initial SOC (%)
0 1.2 2.7 5 <12
25 1.4 3.4 9
50 1.4 4.2
75 2
100

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English FZSoNick

III - Battery Floating

The float power consumption of the battery depends on the temperature of the ambient where the
battery is installed. This behavior is mainly due to the variations of the heat power requirements with
the temperature. The graph below shows the power consumption at different ambient temperatures.

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IV - Battery Performance

Following tables show the capacity and energy at different final voltage levels when the battery is
discharged with a constant current or constant power load.

During a discharge at low temperatures, the internal heaters will consume more energy than at
higher ambient temperatures, but the capacity or energy reduction is minimal. During operation at
high temperatures, capacity or energy is not affected.

- Capacity / Current: Cell discharge behavior: CONSTANT CURRENT

- Power / Energy: Cell discharge behavior: CONSTANT POWER

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English FZSoNick

V - Battery Cool Down

The graph below shows the internal temperature evolution of a battery module during the cool down
process.

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VI – Discharge tables

- 110UP80: CONSTANT CURRENT

110UP80 Capacity [Ah]

[-20 + 60°C; -4 ÷ +140°F]
Termination
End voltage [V]
By BMS 92,4 94,6 96,8 99
Discharge time [h] Ah Vfin
1 61,8 79,2 52,8 48,0 42,0 37,4
2 76,7 79,2 73,4 68,2 60,5 53,0
3 80,0 92,0 79,4 76,2 69,5 60,2
4 80,0 92,4 80,0 79,4 74,8 66,0
5 80,0 95,5 80,0 80,0 77,2 70,0
6 79,4 97,0 79,4 79,4 78,2 72,0
7 78,6 97,9 78,6 78,6 78,4 74,0
8 77,4 98,6 77,4 77,4 77,4 75,2
10 76,1 99,0 76,1 76,1 76,0 76,0
20 68,1 100,3 68,1 68,1 68,1 68,1

110UP80 Discharge Current [A]

[-20 + 60°C; -4 ÷ +140°F]
Termination
End voltage [V]
By BMS 92,4 94,6 96,8 99
Discharge time [h] A Vfin
1 61,8 79,2 52,8 48,0 42,0 37,4
2 38,4 79,2 36,7 34,1 30,2 26,5
3 26,6 92,0 26,4 25,4 23,2 20,1
4 20,0 92,4 20,0 19,8 18,7 16,5
5 16,0 95,5 16,0 16,0 15,4 14,0
6 13,2 97,0 13,2 13,2 13,0 12,0
7 11,2 97,9 11,2 11,2 11,2 10,6
8 9,7 98,6 9,7 9,7 9,7 9,2
10 7,6 99,0 7,6 7,6 7,6 7,6
20 3,4 100,3 3,4 3,4 3,4 3,4

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English FZSoNick

- 110UP80: CONSTANT POWER

110UP80 Discharge Energy (kWh)

[-20 + 60°C; -4 ÷ +140°F]
Termination
End voltage [V]
By BMS 92,4 94,6 96,8 99
Discharge time [h] kWh Vfin
1 5,28 79,2 5,02 4,58 4,22 3,78
2 7,57 79,2 7,04 6,69 6,07 5,37
3 8,10 90,1 7,83 7,57 7,04 6,34
4 8,27 92,2 8,18 8,01 7,66 6,86
6 8,36 96,4 8,36 8,36 8,10 7,57
8 8,36 98,6 8,36 8,36 8,27 7,92
10 8,27 99,0 8,27 8,27 8,27 8,10
15 8,01 99,7 8,01 8,01 8,01 8,01
30 6,60 101,0 6,60 6,60 6,60 6,60

110UP80 Discharge Power (kW)

[-20 + 60°C; -4 ÷ +140°F]
Termination
End voltage [V]
By BMS 92,4 94,6 96,8 99
Discharge time [h] kW Vfin
1 5,28 79,2 5,02 4,58 4,22 3,78
2 3,78 79,2 3,52 3,34 3,04 2,68
3 2,70 90,1 2,60 2,51 2,33 2,11
4 2,07 92,2 2,05 2,00 1,92 1,72
6 1,39 96,4 1,39 1,39 1,35 0,99
8 1,05 98,6 1,05 1,05 1,04 0,99
10 0,83 99,0 0,83 0,83 0,83 0,81
15 0,53 99,7 0,53 0,53 0,53 0,53
30 0,22 101,0 0,22 0,22 0,22 0,22

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- 125UP80: CONSTANT CURRENT

125UP80 Capacity [Ah]

[-20 + 60°C; -4 ÷ +140°F]
Termination
End voltage [V]
By BMS 105 107,5 110 112,5
Discharge time [h] Ah Vfin
1 61,8 90,0 52,8 48,0 42,0 37,4
2 76,7 90,0 73,4 68,2 60,5 53,0
3 80,0 104,5 79,4 76,2 69,5 60,2
4 80,0 105,0 80,0 79,4 74,8 66,0
5 80,0 108,5 80,0 80,0 77,2 70,0
6 79,4 110,3 79,4 79,4 78,2 72,0
7 78,6 111,3 78,6 78,6 78,4 74,0
8 77,4 112,0 77,4 77,4 77,4 75,2
10 76,1 112,5 76,1 76,1 76,0 76,0
20 68,1 114,0 68,1 68,1 68,1 68,1

125UP80 Discharge Current [A]

[-20 + 60°C; -4 ÷ +140°F]
Termination
End voltage [V]
By BMS 105 107,5 110 112,5
Discharge time [h] A Vfin
1 61,8 90,0 52,8 48,0 42,0 37,4
2 38,4 90,0 36,7 34,1 30,2 26,5
3 26,6 104,5 26,4 25,4 23,2 20,1
4 20,0 105,0 20,0 19,8 18,7 16,5
5 16,0 108,5 16,0 16,0 15,4 14,0
6 13,2 110,3 13,2 13,2 13,0 12,0
7 11,2 111,3 11,2 11,2 11,2 10,6
8 9,7 112,0 9,7 9,7 9,7 9,2
10 7,6 112,5 7,6 7,6 7,6 7,6
20 3,4 114,0 3,4 3,4 3,4 3,4

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English FZSoNick

- 125UP80: CONSTANT POWER

125UP80 Discharge Energy (kWh)

[-20 + 60°C; -4 ÷ +140°F]
Termination
End voltage [V]
By BMS 105 107,5 110 112,5
Discharge time [h] kWh Vfin
1 6,00 90,0 5,70 5,20 4,80 4,30
2 8,60 90,0 8,00 7,60 6,90 6,10
3 9,20 102,4 8,90 8,60 8,00 7,20
4 9,40 104,8 9,30 9,10 8,70 7,80
6 9,50 109,5 9,50 9,50 9,20 8,60
8 9,50 112,0 9,50 9,50 9,40 9,00
10 9,40 112,5 9,40 9,40 9,40 9,20
15 9,10 113,3 9,10 9,10 9,10 9,10
30 7,50 114,8 7,50 7,50 7,50 7,50

125UP80 Discharge Power (kW)

[-20 + 60°C; -4 ÷ +140°F]
Termination
End voltage [V]
By BMS 105 107,5 110 112,5
Discharge time [h] kW Vfin
1 6,00 90,0 5,70 5,20 4,80 4,30
2 4,30 90,0 4,00 3,80 3,45 3,05
3 3,07 102,4 2,95 2,85 2,65 2,40
4 2,35 104,8 2,33 2,27 2,18 1,95
6 1,58 109,5 1,58 1,58 1,53 1,12
8 1,19 112,0 1,19 1,19 1,18 1,12
10 0,94 112,5 0,94 0,94 0,94 0,92
15 0,60 113,3 0,60 0,60 0,60 0,60
30 0,25 114,8 0,25 0,25 0,25 0,25

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- 130UP80: CONSTANT CURRENT

130UP80 Capacity [Ah]

[-20 + 60°C; -4 ÷ +140°F]
Termination
End voltage [V]
By BMS 109,2 111,8 114,4 117
Discharge time [h] Ah Vfin
1 61,8 93,6 52,8 48,0 42,0 37,4
2 76,7 93,6 73,4 68,2 60,5 53,0
3 80,0 108,7 79,4 76,2 69,5 60,2
4 80,0 109,2 80,0 79,4 74,8 66,0
5 80,0 112,8 80,0 80,0 77,2 70,0
6 79,4 114,7 79,4 79,4 78,2 72,0
7 78,6 115,7 78,6 78,6 78,4 74,0
8 77,4 116,5 77,4 77,4 77,4 75,2
10 76,1 117,0 76,1 76,1 76,0 76,0
20 68,1 118,6 68,1 68,1 68,1 68,1

130UP80 Discharge Current [A]

[-20 + 60°C; -4 ÷ +140°F]
Termination
End voltage [V]
By BMS 109,2 111,8 114,4 117
Discharge time [h] A Vfin
1 61,8 93,6 52,8 48,0 42,0 37,4
2 38,4 93,6 36,7 34,1 30,2 26,5
3 26,6 108,7 26,4 25,4 23,2 20,1
4 20,0 109,2 20,0 19,8 18,7 16,5
5 16,0 112,8 16,0 16,0 15,4 14,0
6 13,2 114,7 13,2 13,2 13,0 12,0
7 11,2 115,7 11,2 11,2 11,2 10,6
8 9,7 116,5 9,7 9,7 9,7 9,2
10 7,6 117,0 7,6 7,6 7,6 7,6
20 3,4 118,6 3,4 3,4 3,4 3,4

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English FZSoNick

- 130UP80: CONSTANT POWER

130UP80 Discharge Energy (kWh)

[-20 + 60°C; -4 ÷ +140°F]
Termination
End voltage [V]
By BMS 109,2 111,8 114,4 117
Discharge time [h] kWh Vfin
1 6,24 93,6 5,93 5,41 4,99 4,47
2 8,94 93,6 8,32 7,90 7,18 6,34
3 9,57 106,5 9,26 8,94 8,32 7,49
4 9,78 108,9 9,67 9,46 9,05 8,11
6 9,88 113,9 9,88 9,88 9,57 8,94
8 9,88 116,5 9,88 9,88 9,78 9,36
10 9,78 117,0 9,78 9,78 9,78 9,57
15 9,46 117,8 9,46 9,46 9,46 9,46
30 7,80 119,3 7,80 7,80 7,80 7,80

130UP80 Discharge Power (kW)

[-20 + 60°C; -4 ÷ +140°F]
Termination
End voltage [V]
By BMS 109,2 111,8 114,4 117
Discharge time [h] kW Vfin
1 6,24 93,6 5,93 5,41 4,99 4,47
2 4,47 93,6 4,16 3,95 3,59 3,17
3 3,19 106,5 3,07 2,96 2,76 2,50
4 2,44 108,9 2,42 2,36 2,27 2,03
6 1,64 113,9 1,64 1,64 1,59 1,16
8 1,24 116,5 1,24 1,24 1,23 1,16
10 0,98 117,0 0,98 0,98 0,98 0,96
15 0,62 117,8 0,62 0,62 0,62 0,62
30 0,26 119,3 0,26 0,26 0,26 0,26

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 Technical Manual – UP range

- 220UP40: CONSTANT CURRENT

220UP40 Capacity [Ah]

[-20 + 60°C; -4 ÷ +140°F]
Termination
End voltage [V]
By BMS 189 193,5 198 202,5
Discharge time [h] Ah Vfin
1 30,9 162,0 26,4 24,0 21,0 18,7
2 38,4 162,0 36,7 34,1 30,2 26,5
3 40,0 188,1 39,7 38,1 34,7 30,1
4 40,0 189,0 40,0 39,7 37,4 33,0
5 40,0 195,3 40,0 40,0 38,6 35,0
6 39,7 198,5 39,7 39,7 39,1 36,0
7 39,3 200,3 39,3 39,3 39,2 37,0
8 38,7 201,6 38,7 38,7 38,7 37,6
10 38,0 202,5 38,0 38,0 38,0 38,0
20 34,1 205,2 34,1 34,1 34,1 34,1

220UP40 Discharge Current [A]

[-20 + 60°C; -4 ÷ +140°F]
Termination
End voltage [V]
By BMS 189 193,5 198 202,5
Discharge time [h] A Vfin
1 30,9 162,0 26,4 24,0 21,0 18,7
2 19,2 162,0 18,3 17,0 15,1 13,2
3 13,3 188,1 13,2 12,7 11,6 10,0
4 10,0 189,0 10,0 9,9 9,4 8,3
5 8,0 195,3 8,0 8,0 7,7 7,0
6 6,6 198,5 6,6 6,6 6,5 6,0
7 5,6 200,3 5,6 5,6 5,6 5,3
8 4,8 201,6 4,8 4,8 4,8 4,6
10 3,8 202,5 3,8 3,8 3,8 3,8
20 1,7 205,2 1,7 1,7 1,7 1,7

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English FZSoNick

- 220UP40: CONSTANT POWER

220UP40 Discharge Energy (kWh)

[-20 + 60°C; -4 ÷ +140°F]
Termination
End voltage [V]
By BMS 189 193,5 198 202,5
Discharge time [h] kWh Vfin
1 5,40 162,0 5,13 4,68 4,32 3,87
2 7,74 162,0 7,20 6,84 6,21 5,49
3 8,28 184,3 8,01 7,74 7,20 6,48
4 8,46 188,6 8,37 8,19 7,83 7,02
6 8,55 197,1 8,55 8,55 8,28 7,74
8 8,55 201,6 8,55 8,55 8,46 8,10
10 8,46 202,5 8,46 8,46 8,46 8,28
15 8,19 203,9 8,19 8,19 8,19 8,19
30 6,75 206,6 6,75 6,75 6,75 6,75

220UP40 Discharge Power (kW)

[-20 + 60°C; -4 ÷ +140°F]
Termination
End voltage [V]
By BMS 189 193,5 198 202,5
Discharge time [h] kW Vfin
1 5,40 162,0 5,13 4,68 4,32 3,87
2 3,87 162,0 3,60 3,42 3,11 2,75
3 2,76 184,3 2,66 2,57 2,39 2,16
4 2,12 188,6 2,10 2,04 1,96 1,76
6 1,42 197,1 1,42 1,42 1,38 1,01
8 1,07 201,6 1,07 1,07 1,06 1,01
10 0,85 202,5 0,85 0,85 0,85 0,83
15 0,54 203,9 0,54 0,54 0,54 0,54
30 0,23 206,6 0,23 0,23 0,23 0,23

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- 250UP40: CONSTANT CURRENT

250UP40 Capacity [Ah]

[-20 + 60°C; -4 ÷ +140°F]
Termination
End voltage [V]
By BMS 210 215 220 225
Discharge time [h] Ah Vfin
1 30,9 180,0 26,4 24,0 21,0 18,7
2 38,4 180,0 36,7 34,1 30,2 26,5
3 40,0 209,0 39,7 38,1 34,7 30,1
4 40,0 210,0 40,0 39,7 37,4 33,0
5 40,0 217,0 40,0 40,0 38,6 35,0
6 39,7 220,5 39,7 39,7 39,1 36,0
7 39,3 222,5 39,3 39,3 39,2 37,0
8 38,7 224,0 38,7 38,7 38,7 37,6
10 38,0 225,0 38,0 38,0 38,0 38,0
20 34,1 228,0 34,1 34,1 34,1 34,1

250UP40 Discharge Current [A]

[-20 + 60°C; -4 ÷ +140°F]
Termination
End voltage [V]
By BMS 210 215 220 225
Discharge time [h] A Vfin
1 30,9 180,0 26,4 24,0 21,0 18,7
2 19,2 180,0 18,3 17,0 15,1 13,2
3 13,3 209,0 13,2 12,7 11,6 10,0
4 10,0 210,0 10,0 9,9 9,4 8,3
5 8,0 217,0 8,0 8,0 7,7 7,0
6 6,6 220,5 6,6 6,6 6,5 6,0
7 5,6 222,5 5,6 5,6 5,6 5,3
8 4,8 224,0 4,8 4,8 4,8 4,6
10 3,8 225,0 3,8 3,8 3,8 3,8
20 1,7 228,0 1,7 1,7 1,7 1,7

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- 250UP40: CONSTANT POWER

250UP40 Discharge Energy (kWh)

[-20 + 60°C; -4 ÷ +140°F]
Termination
End voltage [V]
By BMS 210 215 220 225
Discharge time [h] kWh Vfin
1 6,00 180,0 5,70 5,20 4,80 4,30
2 8,60 180,0 8,00 7,60 6,90 6,10
3 9,20 204,8 8,90 8,60 8,00 7,20
4 9,40 209,5 9,30 9,10 8,70 7,80
6 9,50 219,0 9,50 9,50 9,20 8,60
8 9,50 224,0 9,50 9,50 9,40 9,00
10 9,40 225,0 9,40 9,40 9,40 9,20
15 9,10 226,5 9,10 9,10 9,10 9,10
30 7,50 229,5 7,50 7,50 7,50 7,50

250UP40 Discharge Power (kW)

[-20 + 60°C; -4 ÷ +140°F]
Termination
End voltage [V]
By BMS 210 215 220 225
Discharge time [h] kW Vfin
1 6,00 180,0 5,70 5,20 4,80 4,30
2 4,30 180,0 4,00 3,80 3,45 3,05
3 3,07 204,8 2,95 2,85 2,65 2,40
4 2,35 209,5 2,33 2,27 2,18 1,95
6 1,58 219,0 1,58 1,58 1,53 1,12
8 1,19 224,0 1,19 1,19 1,18 1,12
10 0,94 225,0 0,94 0,94 0,94 0,92
15 0,60 226,5 0,60 0,60 0,60 0,60
30 0,25 229,5 0,25 0,25 0,25 0,25

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APPLICATION NOTES
A. Battery main features

Sodium-Metal Chloride Batteries belong to the molten-salt battery category. This technology has
high specific and gravimetric capacity, with cells operating at relatively high temperatures (260-
350°C) enclosed in a thermally insulated case.
The ambient operating temperature range of the battery extends about from -20°C to +60°C, without
any power de-rating.
Energy performance is excellent, while the internal cell resistance gives an optimal discharge rate
between 1 and 8 hours.
Typical cell failure mode is low-dissipation internal short-circuit, therefore guaranteeing battery overall
performance with this unique graceful degradation feature.
A sealed steel cell case provides for zero ambient emissions and allows the battery installation in
any closed environment.

B. Electrical differences with other battery types

The main differences between a conventional room-temperature battery (e.g. Lead-Acid) and a
Sodium-Metal Chloride Battery are following:

1) Sodium-Metal Chloride Batteries can exchange energy only when their internal temperature
reaches the minimum operating temperature of about 260°C.
2) A Warm-Up time shall pass before the battery could be brought into operation
3) All batteries have an integral charger and shall be connected only to a Constant-Voltage DC
Bus when charging
4) Maximum DC Bus voltage limits shall be respected at all times, in order to avoid damaging
internal control electronics
5) Sodium-Metal Chloride Batteries cannot be series-connected

The BMS includes the power electronics circuits to control the resistive heaters and the charge
process and by a microprocessor that supervises the complete operation of the battery.
The resistive heaters will be switched on and off by power Mosfets with a PWM control at about
300Hz.
Integrated step-down (Buck) DC/DC converter charge regulators have a switching frequency of 45
kHz (one for each cell string).
Default, maximum charging current of each string is 8 A. Charge Current can be programmed for
lower levels.
The external source (charger, rectifier or bi-directional inverter) should provide a stable voltage
working as voltage generator and should include a soft start function to avoid overvoltage peaks that
could damage the battery electronics.
When a battery is switched on, the BMS shows a capacitive load and then the internal power
supply starts and powers up the micro-controller with a load of about 10 watts.

If a BMS is plugged to an already powered DC BUS the resonance of the capacitive load with the
inductance of the bus could lead to an overvoltage dangerous for the electronic circuits. The DC
bus must show a low inductance and/or the system must be equipped with a Surge Protective
Device capable to limit the overvoltage.
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C. Warm-up

As soon as the battery is connected to a constant-voltage DC Bus within the specified range,
it starts warming its cells from ambient temperature to 260°C. Throughout this phase, the
battery is a switched resistive load, consisting of a PWM-controlled heater, with a switching
frequency of 310 Hz
The power source must provide a stable voltage in presence of a switched load.
 During the 12-13h warm-up period, the battery draws a constant power from the DC Bus. Due to
internal cell structure, no charge can be exchanged with the cells during warm-up, therefore all
circuits are disconnected by holding the battery contactor open (Main Switch)
 From a user point of view, even low currents cannot be drawn from the battery during warm-
up: if the DC Bus is switched off, its voltage is not held by the battery and drops to zero
 If power is removed during the warm-up process, the battery begins to cool down at a rate
between 5°C/h and 2°C/h (in the temperature ranges 250...150°C and 150...50°C
respectively). Warm-up resumes as soon as DC Bus power is restored.
 Being the battery a switched resistive load, no excess power can be dumped into the battery.
If for any reason this is attempted, DC Bus voltage will rise possibly to dangerous voltages
for the BMS electronics
 Maximum Vbus voltage is specified in Table 1 and can never be exceeded even for short
transients. Compliance to this limit should be verified by the System Integrator
 If for any reason Vbus voltage exceeds the maximum allowed, the battery could be
permanently damaged and will need to be shipped back to the manufacturer

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D. Charge

 The battery closes the Main Switch and turns on its internal charger as soon as it reaches
the operating temperature
 During charge the power source must work as voltage generator and keep the voltage within
the specified limits (Vbus_min...Vbus_max) in presence of a variable load : A CC/CV charge
profile is applied until all the cells are brought to an EOC (End-Of-Charge) condition.
 The charge process is always managed by the internal DC/DC: the current of each string is
controlled and slowly reduced to keep a maximum current/maximum voltage control and the
absorbed power tapers down in time from Pcharge_max to Stand-by power
 If the DC BUS voltage will decrease below Vmin the charge will stop, if the DC BUS voltage
will further decrease below the battery open circuit voltage,the battery will switch to
Discharge condition.
 For this reason, during the charge, NO excess power can be dumped into the battery. If this
is attempted for any reason, DC Bus voltage will rise to possibly dangerous voltages for the
BMS electronics
 The minimum current before the detection of the complete charge could be low as 0,2 A.per
string
 During the charge process the BMS will also control the heaters with the power necessary to
keep the battery temperature at the heating set point.

To charge the battery the power source (rectifier, power supply or bi-directional inverter) must
work as voltage generator and provide a stable voltage in presence of a variable load .See
section H for the maximum acceptable ripple

E. Stand-by / floating mode

 after charge current has dropped under a set value, the EOC condition is reached: the internal
charger is turned off and the battery goes into the “Stand-by” (or “Float”) state
 when in this state, the battery draws only “Stand-by Power” from the DC Bus. The BMS will
control the heaters with the power necessary to keep the battery temperature at the heating
set point. The power request depends on the ambient temperature
 in this condition the battery can instantly deliver power and hold the DC Bus through its output
diode, supplying all bus loads until its energy is over
 in this condition the battery cannot instantly absorb charge power.
 Its internal power circuits have to be steered and a current ramp will begin within hundreds
of milliseconds from the DC Bus being restored

The power source must provide a stable voltage in presence of a switched load. .See section H
for the maximum acceptable ripple

F. Discharge

 the battery can instantly deliver power and hold the DC Bus through its output diode,
supplying all bus loads until its energy is over.
 the BMS includes an electronic fuse that protects the battery from any overcurrent abuse
 As soon the voltage on the bus recover, the battery will be set back in charge mode
 The discharge will be terminated if then battery is discharged, or the maximum current ,
maximum temperature or minimum voltage limits are exceed

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G. Overvoltage protection

The maximum Vbus voltage can never be exceeded even for short transients.

The charger/rectifier should provide a stable voltage working as voltage generator and in
presence of transients should react fast enough to avoid overvoltage peaks on the DC bus that
could damage the battery. The system must be equipped with a Surge Protective Device
capable to limit the overvoltage on DC bus.

If the BMS detects a voltage higher than V Max the main switch will be open to protect the cells
but in any case some electronic circuits of the BMS will remain connected to the DC bus and
can be damaged by the overvoltage

V MAX [Vdc]
Time [msec] 110UP80 125UP80 130UP80 220UP40 250UP40
1000 154 175 180 308 350
100 165 190 197 335 380
30 180 204 210 360 410
10 194 220 230 385 440

Special care must be taken in systems where it is not possible to prevent energy sourge to be
dumped in the DC bus.

Examples of such systems are some UPS/PCS applications where capacitive / inductive
energy surges are dumped into the standard Lead Acid batteries.
Such system must be equipped with a convenient Surge Protective Device to prevent
overvoltages.
Clamp Peak/Sustained power ratings shall be determined after a careful evaluation of the
worst-case energy surges that may be expected during the operational life of the system.

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H. Ripple

High ripples on the DC BUS generated by the power electronics could damage the BMS

The maximum acceptable ripples is

Frequency range V rms

50-300 Hz 2% V nominal

10-40 kHz 2% V nominal

In order to limit the ripple a capacitor pack must be installed as close as possible to the battery
module

OVERVOLTAGE CLAMP APPLICATION

Capacitor sizing shall be determined after a careful evaluation of the worst-case that may be
expected and/or real measurements of the system.

NOTE:
In case the current drawn by the inverter from the battery presents a prevalent half wave variable
profile the user shall consult the battery supplier to apply appropriate filters to mitigate it, otherwise
the warranty is void.

As an example this situation has been found in three-phase inverters with capacitor midpoint
topology and unbalanced loads.

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Title Issue Date Revision

Technical Manual - UP range 2020-12-15 Draft
Technical Manual - UP range 2021-02-18 Draft01
Technical Manual - UP range 2021-08-25 Draft02
Technical Manual - UP range 2022-01-28 Draft03

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