USER MANUAL
Maxwell Technologies
®
Ultracapacitor Energy Storage Modules
Models:
16 V Series:
BMOD0500
BMOD0500
BMOD0250
BMOD0110
P016
P016
P016
P016
B01
B02
B01
B01
48 V Series:
BMOD0165
BMOD0110
BMOD0083
BMOD0165
BMOD0165
P048
P048
P048
P048
P048
B01
B01
B01
B06
B09
Document 1008491
Please contact Maxwell Technologies directly for any technical specifications critical to application. All products featured on this
user manual are covered by the following U.S. patents and their respective foreign counterparts: 6643119, 7102877, 7180726
7203056, 7295423, 7342770, 7352558, 7384433, 7440258, 7492571, 7508651, 7580243, 7791860, 7791861, 7816891,
7859826, 7883553, 7935155, 7859826, 7883553, 7935155, 8072734, 8098481, 8279580 and patents pending.
MAXWELL TECHNOLOGIES, MAXWELL, MAXWELL CERTIFIED INTEGRATOR, ENABLING ENERGY’S FUTURE, BOOSTCAP, C
CELL, D CELL, CONDIS, RAD-PAK and their respective designs and/or logos are either trademarks or registered trademarks of
Maxwell Technologies, Inc. and may not be copied, imitated or used, in whole or in part, without the prior written permission
Maxwell Technologies, Inc. All contents copyright © 2014 Maxwell Technologies, Inc. All rights reserved. No portion of these
materials may be reproduced in any form, or by any means, without prior written permission from Maxwell Technologies, Inc.
1. Introduction
The 16 V and 48 V series energy storage modules are self-contained energy storage devices
comprised of either six or eighteen individual ultracapacitor cells, respectively. The modules
include bus bar connections and integrated cell balance voltage management circuitry. Units may
be connected in series to obtain higher operating voltages, parallel to provide additional energy
storage, or a combination of series/parallel arrangements for higher voltages and energy. Voltage
management and alarm circuits function to protect each cell from operating in a damaging
overvoltage condition.
The module packaging (except for BMOD0110 P016) is a heavy-duty aluminum extruded
enclosure. The enclosure is a sealed, water-resistant device (per IEC 529 – IP65). The package
for the BMOD0110 P016 consists of a plastic housing with a metallic cover for thermal transfer.
The voltage management electronics have a single open collector logic output (except for models
with “B02” suffix) which indicates if any cell within the module is experiencing an over voltage
condition. Each module contains one temperature monitor output in the form of an NTC
thermistor.
2. Unpacking and Handling
2.1 Unpacking
Inspect the shipping carton for signs of damage prior to unpacking the module. Damage to the
shipping carton or module should be reported to the carrier immediately. Remove the module from
the shipping carton and retain the shipping materials until the unit has been inspected and is
determined to be operational.
The following items are included with the module:
1
1
1
1
x
x
x
x
Product Information Sheet
Certificate of Conformance
Hex head cap, M10x16, Zinc plated screw
Hex head cap, M8x16, Zinc plated screw
NOTE:
The original shipping materials are approved for both air and ground shipment. The
module should be removed from the shipping carton by lifting it by the module body and not by
the terminal posts.
If the unit is found to be defective or any parts are missing, contact your supplier. A Return
Material Authorization (RMA) number must be issued prior to returning the unit for repair or
replacement.
2.2 Handling
Maxwell ultracapacitor modules are designed to provide years of trouble-free operation. Proper
handling is required to avoid damage to module. In particular, the following handling precautions
should be observed:
Do not stack modules once they have been removed from the shipping containers.
User Manual – 16 V and 48 V Modules
– Doc. No. 1008491.13
© 2014 Maxwell Technologies, Inc.
Page 1
Do not drop modules.
exterior.
Do not step on modules.
Internal damage may occur that will not be visible from the
Protect the PCBA cover from impact. If any damage occurs to the PCBA cover, contact
Maxwell for replacement instructions.
Do not use tools such as hammers to disengage mounting or terminal bolts. Serious
damage may occur.
3. Installation
3.1 Mechanical
Modules may be mounted and operated in any orientation. Two mounting surfaces are available
(except for BMOD0110 models); one at the top and the other at the bottom surface. These top
and bottom plates are designed to support the module with no additional mechanical contact. See
the data sheet for available mounting locations. The BMOD0110 models may only be mounted with
the bottom side down to the mounting surface.
For best results the modules should not be mounted in locations where they are directly exposed
to the environment. In particular, areas of direct splash should always be avoided. In systems
that operate at voltages in excess of 60 V, appropriate protection and sealing should be used on
both module terminals to avoid shock hazards and corrosion.
A proper installation should not exert any bending or twisting torque to the module enclosure.
Ensure that the module’s mounting points are co-planar within ±1 mm. If the actual mounting
location is out-of-plane, use spacers to bring all four mounting locations within plane to within
±1mm.
Modules (except for BMOD0110 P016) have been qualified to SAE J2380 for vibration performance.
Ensure that this is adequate for the end-use environment.
Each module is provided with a threaded vent hole on the top plate. The module is shipped from
the factory with a vent plug in this vent hole. The use of the vent is optional. If the application
recommends/requires remote venting, a threaded hose barb can be provided upon request.
To use the hose barb, remove the vent plug which is in the hole when the module is received and
replace it with the hose barb. Attach a 5/32 (4 mm) ID hose, preferably Teflon or polypropylene,
to the hose barb and route the hose to a safe venting location. In the event of cell venting, the cell
may release gas, which will build pressure in the module. That pressure can be relieved through
the vent tube.
User Manual – 16 V and 48 V Modules
– Doc. No. 1008491.13
© 2014 Maxwell Technologies, Inc.
Page 2
3.2
Electrical
WARNING
To avoid arcing the energy storage module should be in a
discharged state and the system power disconnected during
installation. The module is shipped discharged and with a shorting
wire. The shorting wire should be removed prior to electrical
connections.
To provide the lowest possible ESR the energy storage modules are
not fused. Care should be taken within the application to prevent
excessive current flow as required. Excessive current and/or 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.
Module-to-module cabling should be sized for the applications peak and/or RMS current.
Undersized cables may cause excessive cable or interconnect temperature rise and system
electrical resistance. High resistance wiring/cables or module power connections will increase
terminal cell temperature and degrade module lifetime and long term performance. Reference
applicable wire sizing guides. Wire temperature must not exceed module temperature.
Note:
The module chassis should be grounded to the system chassis through any of the module
mounting holes. Refer to applicable ground wiring guides and standards for the application.
The anodized coating of the module on the ground connection surface should be removed to
ensure an optimal electrical contact. Apply a layer of high conductivity anti-oxidant joint compound
between the mating surfaces (IDEAL Noalox
®
Anti-Oxidant Compound or equivalent).
3.2.1 Output Terminal Posts
The output terminals of the module consist of internally threaded aluminum posts. They are
designed to connect directly to a ring lug or a bus bar. Maximum thread depth is 20 mm. If ring
terminals and lock washers in excess of 10 mm are to be used, a longer bolt must be selected. In
no instance should the total amount of thread engagement be less than 10 or greater than 20 mm.
The terminal contact surface should be cleaned with a light abrasive such as Scotch-Brite
TM
to
remove any oxidation. Apply a layer of high conductivity anti-oxidant joint compound between the
mating surfaces (IDEAL Noalox
®
Anti-Oxidant Compound or equivalent). The positive terminal is
threaded for M8 x 1.25 steel bolts. The negative terminal is threaded for M10 x 1.5 steel bolts.
Lock washers are required for long term, reliable connections. For additional performance, a
thread locking compound such as Loctite
®
425 may be used. However, care should be taken that
the thread locking compound does not come in contact with the electrical mating surfaces.
When tightening the terminal bolts, a torque of 20 N-m / 14.8 ft-lbs for the M8 and 30 N-m / 22.1
ft-lbs for the M10 bolts should be used. Do not exceed recommended torque.
User Manual – 16 V and 48 V Modules
– Doc. No. 1008491.13
© 2014 Maxwell Technologies, Inc.
Page 3
As in any electrical system, proper cable dress is required for trouble-free operation. The cables
used for attachment are large, and improperly constrained cables can place bending stress on the
terminals and terminal bolts. Cables should be installed so that they do not exert bending or
twisting torque on the power terminals, and should be routed away from the module so that they
are parallel to the top surface of the terminal and constrained within 50 cm of the terminal before
bending the cable in any direction. High vibration environments may require additional restraints.
Attachment to the output terminals should be made with ring lugs or bus bars of an appropriate
size for the application current. If bus bars are used, brackets should be installed to interconnect
the tops of adjacent modules to prevent undesirable lateral forces on the terminals.
The energy storage modules have low ESR. As a result, the resistance of the wires connecting the
energy storage module to the application can easily exceed the ESR of the module. Connection of
modules in series or parallel should utilize the same gauge wire (or equivalent bus bar) 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. Two possible
orientations are illustrated in Figure 1.
Figure 1 – Possible series connection arrangements
Full UL810a compliance is satisfied for up to three (3) BMOD0165 P048 (certain BMOD0165 P048
B09 models may not be UL810a compliant) modules in series or nine (9) BMOD0500 P016 modules
in series (maximum operating voltage of 150V).
When several modules are connected in series for operating at higher voltage, care must be taken
to ensure proper creepage and clearance distances in compliance with national safety standards
for electrical equipment.
User Manual – 16 V and 48 V Modules
– Doc. No. 1008491.13
© 2014 Maxwell Technologies, Inc.
Page 4
京公网安备 11010802033920号
EEWORLD
